GIPSY G4mi0 & G4mis VEHICLES WORKSHOP MANUAL LIMITED ENGLAND , Oxford MiEN TE RODWCT LON ssary information fer them This Manual has heen prepared to pravide the service nce book for service supervision, but also and repair of these vehicles. The Manual serves not ouly as a ready covers items of procedure for the guidance of both the fully qualified and the less-experienced mechanic. The following notss will simplify reference to the information the Menual contains letter referenc Unit urrasgemont, The complete vehicle is broken down bered consecutively within each Section ‘Numbecing of pages and illasteations. The pages and illustrations are Section title and letter, in addition to each page number, are shown on each pa and thi Service tools. Proper taols contribute largely to efficient, economic, and profitable repair. References have therefore been made to such tocls throughout the ManualCONTENTS Introduction General Dats Maintenance Attentions 'etvol Engine z goition System (petrol models) Cooling, System (petrol models) Fuel System (petrol a Clutch Gearbox Propeller Shatt Rear Axle Steoring Gear eee Front Axle Road Springs and Dampers Braking System Electrical Equipment (petrol models) Wheels and Tyres ubrication (petrol models Lubrication (diesel models) cl ion Cha 4 ¢ i G ri N End of BookdOL LAOS OLD A841 NEES THEdN-MDId SUNPO ASAIO NLLSOY SHEGENERAL PETROL ENGINE Type Numbes of eylinders Bors Sirake Capacity Compressit Fira Maximom bhp. Maximum torgue Oversize bore: First Second Third, Mex ratio Crankshaft Journal diameter Crankpin diameter Undersizes (journals and crankpins): First ‘ Second Thi Max. End-float (taken on chrust washers at centre main bearing) Main bearings Number Type Length: Front and. Rear Running clearance Undersses for reground jours Side-siearance 1 igre bearings ‘Type Length a Inner diameter Running clearance Undecsizes for reground crankpins - Pistons M Clearance at bottom of skirt Width of groove: Compression Oil contro Oversizes Piston rings Number i Width: Compcession : Oil contro ed): Compression Oil contro} é Gap ( DAT A 22NA. 5 in. (79-4 mm in, (11341 mm.) in, (2199 ¢.c) 010 in, (254 min.) 020 in. (508. mm.) (030 in. (762 mm.) °040 in. (1-016 mm}, 2.4700 ta 2-4795 in. (6 2.0000 ta 2-005 in, (S08 to $0813 im (010 in. (254 mm.) 020 in. (508 mm. 020 in. (762 mm.) 090 in. (1-016 mm.) 002 to -103 in. (051 to “076 mm). 2.987 10 62979 mm.) Steel-backed white m: 1} in. 44-4 mm.) 2in, (508 mm), 02S te -063 fun.. ‘Ceankshuilt 81830 to 81879 in, (207-848 to 207-963 mm.) 08 10 O12 in, (203 10 305 mm.) Steel-backed white metal 1-226 to 1-236 in. (1-140 to 31-394 mm.) 2.001 to 2-002 in, (50-825 to 50-850 mm.) ‘0005 to 002 in. (0127 to -0508 mm). See under “Crankshatt’, Aluminium alloy. 008 to O14 in. (920 to 036 mm). 957 to -0967 in, (2-430 to 2-456 mm.) +1895 to “1905 in, (4-813 to 4838 mm). ‘See under “ENGLNE’. 3 compfeasion (1 plain, 2 taper), 1 oil contro ‘hin, 238 mm) fe in. 476 ine. 108 to O14 in. (2286 to -3856 mm. 008 10 -O12 in, (203% to 3048 mm.) General Data tGENERAL DATA—coatinued Gaudgcon pins Type ave ; Fitin piston... Diameter . ae Length. Valves Position : Litt : Diameter: Head: Inlet Exhaust ; Stem: Inlet and exhaust Stem to guide clearance: Tnlet Exhaust Valve to rocker clearance ase Seat angke Valve guides Length: Inlet 3 Exhaust . Fitted height above head Diameter: Outside: Inlet and exhaust, Inside: Inlet Exhaust ‘Valve speings Free length Fitted length Pressure: Valve closed Wire diameter 2 Core diameter Fea “Tappets ‘Type 5 ‘Rechbrs Bubhes—inside diameter (reamed in position) Bore of arm : Camshaft Journal diameter: Front Contre Rear © End-float (laken on thrust plate at front end) (Camshaft bearings ‘Number Type 2 Inner diameter (reamed in position): Front Centre Rear. Running ckarance ‘Valve timing ‘Chan pitch and number of pitehes -. ‘Valve to rocker clearance timing check Inlet valve: Opens. Closes. 0 ‘Exhaust valve: Opens a as Closes. : General Date 2 Clamped, : 001 in. (0025 mm) clearance to -0003 in, (0076 mm.) interference, 8743 10 -8750 in. (22°22 to 22225 mm.) clearance, 2.75 in, (69-85 mm). Qeethead, pushrrod-operated, 340 in. (9-906 mam.) 1-500 to 1-605 in. (40-64 to 40-987 mm). 1-415 to 1-420 in. 35-991 to 36-068 mm.) Mia, G71 mm), 0155 to OUDSS in. (089 to O64 mm.) {00105 to 00205 in. (027 to 052 mm.) 12 in, (30 mm.) ” 2e in. (54-971 mm, 2H in. 7F8M mm). {fio J in, (175 to 19 mm). “5635 to “S640 in, (14-312 ta [4-325 mm). 337 to 338 in, (8559 to $-S85 mm.). 53433 to “3438 in, (8-720 to 8-733 mm.) Lif in. (54-244 mm), 1526 in, 8-76 mm), 5] to 55 Ib. (23-14 to 24.96 kx). 176 in, (447 mm, 1-125 to 1140 in, @8S2S to 28-985 mm), Cylindrical. 8115 to “$125 in, QU61 16 20-64 mim). 909 to -910 in. (234088 to 23-114 mm). 1.78835 to 1-78925 in, (45-434 to 45-446 mm}. 1.74875 to 1:74925 in. (44-418 to 44431 mm). 1:62273 (0 1°62323 in, (41-217 to 41-236 mm). 003 £6 -006 in. (076 to 152 mien.) 3. Sicel-backed white metal 1.79025 to 1-7907S in. (45-472 to 45-485 mm). 1.75025 to 1.75075 in. (44456 to 44-469 mm). 1462425 to 1962473 in, (41-256 to 41-269 mm). 001 to -002 in, (025 to 051 mm.) 375 in. (9-525 mm); €2. 21 in. (-533 mm.) s. BTDC. 45°, ABDC, 40°. B.B.D.C. 1 ATD.C. ss,GENERAL DATA—eontinued Engine lubrication system System. Pump (ype External filter Oil pressure: Ealing. Normal running Release valve spring: Frec length, Operating pressure EL ENGINE Type Number of cylinders Bore te Stroke Capacity Compression ratio Finng order. eis ae Maximum b.h.p. Maximum torque {ling speed a es Maximum governed light running speed é Maximum governed speed under load Oversize bore: First Second : tae Max. (Crankshaft Journal diameter Crankpin diameter és Unilersizes (journals and erankpin): First Second, Third Max. - Endlont (taken om thrust washers at esntre main bearing) Main hearings 3 ‘Number » piyoe sed ae eens cea S Length: Front and contre Rear oF a - Running clearance ‘Undersizes for reground journ Connecting rods Length (centres) k Side-clearance we Smallend bush (laner diameter, reamed in position) Big-end bearings Type... a . Length é Inner diameter Running clearance . Aaa eae ‘Undersizes for reeround crankpin Pressure, Escentric rotor. Full-flow Tevalemic or Purolator, 15 th,jsq. in. (1405 ke. feat. 50 Ib,/sq. in. (5 kg.iem. 3in, (762 mm.) 50 to 55 Ib./sq, in 5210987 ke.fem.) 2QUA. 4 3-2495 10 $2510 in. (82-597 co 82575 mm.) 40 in, (101-6 mm, 132-7 ev. in. 2178 co 2:1 1.34,2, Sat 3,500 rpm, 89 1b. ft at 2,800 r p.m, 600 p.m, 3,700 rpm. 3,500 ropa. “010 in. (254 mm. 020 in, (508 mm.) 1030 in, (762 mm. 24780 to 2-4785 in. (2-941 to 62-954 mm.), 2.2480 to 2-2485 in. (7099 to 57-112 ma). 10 in, (254 mm 4020 in. (508 mam.) 030 in. (762 mm.) 040 in. (016 mm). 002 to 903 in, (051 to. -076 mm.) 5 Steel-backed lead-indium, 16625 in. (41-275 mm), 1875 in. (47-625 mm), (002 to 035 in, (051 to -089 mm). See under *Crankshal’. 7-999 10 8-001 in. (20317 vo 20323 mm. (008 to 12 in. (203 to 305 mm) 1:(235 to 1+1260 in, (28:588 10 28-600 mm.) Seeel-backed lead-indium. 995 to 1-U0S in, 25-27) to 25-527 mm). 2.2515 in. (57-188 mm), 902 in. (051 (0 089 mum). See hat.GENERAL DATA—coatinued Pistons J eee é Clearance at bottom of skirt Ro ‘Width of groove: First compression Second and third compression Oil control BEY Oversee Piston rings: Number Width: Compression 7 Oil control Gap (compression and oil control) Gudgeon pins Type a ee Fitz Ia piston. In connecting rod. Diameter Length. Valves Position Lite Diameter: Head: Inlet Ce shat! Stem: Inlet and exhaust -- Stem to guide clearance: Inlet Exhaust Valve to rocker clearance : Seat angle, inlet and exhausts: Seat face width: Inlet .. nae Exhanst 4 Valve guides Length: Inlet... = Exhaust é Fitted height above head Diameter: Outside! Inlet and exhaust Inside: Inlet (reamed in position) Exhaust 3% Valve springs Free longth: Ianor eed Outer ae a Fitted length: Inner . Outer eae Pessure: Valve closed: Inner : Guter _ Working coils: Inner Outer - fans Wire diameter Incer ate Outer Core diameter Inner. Outer -. Aluminium alloy. 004 to -0046 in. (102 to -L17 mm.) 0975 to 0985 in. (2.477 to 2-502 mm.) 9865 10-0975 in, 2451 to 2-477 mes) BMS to +1895 in, (2.788 to 4813 mm} ‘See under “ENGINE’. 3 compression (1 chrome-faced, 2 parallel, internally stepped), 2 oil control. 9928 to -0938 in. (2.397 t0 2383 mm). 1865 to “1875 in, (4737 to 4-763 mm.) 009 to -O14 in, (228 to 356 mm.). Floating, located ia piston by circlips 9003 in. (C08 mm.) clearance fo 0005 in. (O18 mm», interference. 9005 to -0033 in. (013 10-035 mm. [1247 to 11250 in, (28°567 to 28-575 mm.) 2-962 Lo 2-772 in. (0-155 10 79-409 mm.) Overhead ond push-rod-operated, 39 in, (99 mm). 1-605 t0 1-610 in. (40-77 to 40-89 mm} 3215 to 1-3268 in. (23-566 to 33-693 mm.) 34175 to 34225 in. (8-680 to 8.693 mm.) 40015 to -0025 in. (038 10 -064 mm.) -Q01 to -002 in, (-025 to OSI mm). “912 in, (305 mm.) cold. 45 11954-0005 in. (4985-083 mm} 199-£-0025 in, (505.1 -063 mm.) 2441 in, (5437 mm). 25 in, (63°5 mm.) 734 +0 -750 in. (18-64 to 19:05 mm). 5835 10 +3640 in. (14°313 to 14-326 mm.) 3438 to “3443 in, (8-733 to 8745. mm.) 3433 to 3438 in, (8-720 to $793 mm.) 3487 in, (5555 mm.) 2S in, (63°S mm, 15 in, G81 mm. 1-703 in. (4326 mm). 23 ta 25 th, (1043 to 11M kg.) 56:5 to 60-5 Ib, (25-63 to 2744 kg,), a 34. 104 in, (2464 mm). 156 in. G97 mm. 75 to 765 in, (1905 to 1943 mst). [25 to 1-140 in, (8:58 to 2896 mmm.)GENERAL DATA— ‘Tappets Type Rockers Bushes—inside diameter (reamed in position) =... Bore of arm Camshaft Journal diameter: Front Centre Rear End-float (tukew on chust plate at front end) Camshaft bearings Number Type Inner diameter (reamed in position): Front, Centre Rear Running clearance Valve timing Chain pitch and number of pitches Valve to rocker clearance for timing check Exhaust valve: Opens . Closes. Engine lubrication system System a Pump type External filter _ Oil pressure: Tdling ‘Normal running Release valve spring: Free length Operating pressure IGNITION Distributor pe aie eeeeerce 2 seis: sf Rotation : Gap : Centrifugal control springs Sie ae ee Coil type. ‘ Slatic ignition timing ee Sparking plug type a Gup ‘ COOLING SYSTEM Circulation Thermostat opening temaperatwre Fan belt type FUEL SYSTEM Pecrol models Fuel delivery... irclanr 6. ntinued Cylindrical. 20-61 to 20-64 mm.) 988 to 23-114 mm.) BL15 10 8125 in, 909 to 910 in. 2. 1-78875 10 1:78925 in, (45-43 10 45-447 mm.) 1-74875 to 1.74925 in. (44-418 to 44431 mm), 1-62275 to 1-62325 in, (41-218 to 41-231 mm.) 003 10 006 in. (076 (o 152 mm.) 3 Steelsbacked wh 1-79025 10 1:79075 in. (45-472 to 45-485 mm.) 1-75025 to L-7S07S in. (44-456 to 44-469 mm.) 1-62425 (0 1-62475 in, (41-256 to 41-269 mm.) 001 to 002 in, (025 to -051 mm.) ce metal “315 in. (9-525 mina; 94 021 in. (53 mm} SBTDC. 40° A.B.D.C. 21 in. (53 mm.) 60° B.B.D.C. | valve to rocker clearance, SATDC Pressure, Eecentrie rotor. Fullsilow Tecalemit. 15 Ib /sq. in. «L085 Kp. fom4. 45 to 50 Ib fog in, (3164 to 3515 ke-fem.?) 3 in. (762 ma.) 50 to 55 Ib,/sq. in. 3:52 to 3°87 ky./om.) 25D. Clockwise, looking on drive end 914 0 016 fn. (356 to 406 mm). Lucas No, 424629 (2 off). HAL Approx. 62° B.C. ‘Champion XNB, 924.40 026 in, (61 t6 -66 mm.). Pump and thermostat (pressurized). 1a" F. (73°C). Wedge. 5.U. electric pump, type SP. (il bath type. Genera Data §GENERAL DATA~—continued CCarbureter type Zenith 42VN downdraught. Carburetors Choke tube ‘ 26 am Main jet : us By-pas et \ iio Slow-running Progression jet 2100 Pump iet @ Fall throttle bleed nie ee Needle 225 mum Diesel mods Lit pump SU, eesti Type : Sige Injection pump CAN, Type i 21) DPAS2«a7¢0n Injectors one Sie Nozzle type Pinta BDN. 12 SPC.6290, Nozze holder pe ol BKBasSs136 Opening prssure 135 atmospheres Main filter 21) CANE bowles. Type : 11) esse, suti njction timing 0 tarps cuurcu Ve e | Petrol engiae Borg & Beck, Single dry plat. diameter Sin. 228 em) | Total frictional area . . . ++ 65-8 sq. in. (424'5 cm.*), | Thiknss of friction sing 150 in, (38 em). } Release beating ) Ball ace amber of thrust springs is. \ Ientcation colours of thrust sptings 1.12 Yellow and ight geen Total axial apring pressure 1215 to 1.305 I. (551 to 592 ke) Thrust plate travel to fly released position 42 t0 Tin, (1067 10 ¥194 om} Diesel engine Make a Botg & Beck wie, Type Sinale dry plate. Beep, ouciee diameter fue foe ole Orten) Mol fictional area . ‘le pila. in, 6022 em), Thickness of ficon lining 150 in (38H om) Releese beating Ball race Number of thrust epriags | : v. Identilcation colours of thr! spcings Light green Total axial spring pressure {260 t0 1,380. (572 to 626 ka) k Thrust place wavel vo fully released position $0 to 54 in, (1-27 to 37 em), I MAIN GEARWOX Ratios & Top emt i Tata ea lett! | Second 2338 i i is i ae te | Revers | abe Bsc eta ei k Geom Dats 6 | ve Wimatcs ~ 4GENERAL DATA—coutinued Bearing dimensions Mainshaft rear ball bearing Ficst motion shaft ball bearing ‘Mainshatt spigot needle rollers Quantity Dimensions Mainshaft second speed gear needle rollers Quantity ‘Muinshaft third speed gear needle rollers ‘Quantity Dimensions Layshtait needle rollers, fromt and rear Quantity sorte Dimensions. TRANSFER GEARBOX Ratios High Low Ball beating dimensions ‘Froat drive shaft Rear drive shaft Intermediate shaft needle rollers Type Speedometer pinion ratios 65016, 70016, 89015 tyr0s 6-00—16 tyres PROPELLER SHAFTS Tye ee ae ‘Make and type of joints REAR AXLE Tyee oi es Ratio ‘Number of gear teeth STEERING Type Steering gear ratio Diameter of steering-whee| Turning civele Torin. Caster angie Camber angle : King pin inclination FRONT AXLE ) dy < OSI os oe amie ‘Number of gear tect : © 3p in. x 1b in. oc zim, 485 mors. 109 mam, 25 mm. 19. 39.8 mm <4 mm. 33. 29-8 mm. «3S mm, 32 298 mm.%35 mm, 166 (33 each bearin, 39:8 mm. 3 mm. 140 (rear-whecl-drive only) 202 (feur-wheelsdrive), ‘2mm. <30 mm.%19 mm. (2 off) (Front) 3} in. x1} in. x} in (Rear) 72 mm. 30 mn. s¢ 19 mm. Hypoid gear drive, three-quarter-flouting, S125: 1 Bl Cam and lever We. 17} in, (43-815 em.). 43 fe. (12192 m) approx. in. 258 mm). a ue ah. Hypeid sear drive, fully floating. General Bata 7GENERAL DATA—continued ROAD SPRINGS AND DAMPERS Front Rear (G4A010), Rear (GMS) ‘Road springs Number of leaves 6 7 o | ‘Thickness of leaves & in. 4-763 mm.) Fin, (635 mm.) din, 635 mm.) | Width of leaves rs + 2 in, (63-5 mm.) 2} in. (57-15 mm.) 2b in. (S715 mm.) Camber (G0 No. 1 fea): Laden Hin. COE mm) | On GO mm) — | O in. O-0 mm) Length between eye centres (laden) .. 36 in, (92 m,) 48 in, (122 m) 48 in. (122 m.) Lond eee | asa tb. 44 kg.) | 1,120 tb, (508 Ke.) | 1,344 Ib, G10 ke) Deflection p | 589 in, (68606 mm] 492 in, (124968 mm) in, (0-6 mm.) Spring dampers ek | Telescopic Lever type BRAKES Make. mae a Eling Foot brake = Ll Mydrautic Hand brake ; Tl Mechanical, on reaéwhedl Drum diameter: (GAMI0) sy 10in, 54 em). ( (GIMIs) fT. ein @7-94.em,. Total Hining area: (G4MI0) 1. 133 sq. in. (858 cm), (G4M135) +. 189% sq. in. (1220 om: ELECTRICAL SYSTEM Petrol models Battery: Make. 5 Lucas Lv Wiring - «. Single-pole, positive (4) earth return. Starter motor peo gee ann Lucas MATSG. Dynamo... 2 tatcas 45 Control box oo alias Diesel models Dynamo. Luweas. ‘Type . . - - - CAG, 12-valt. Starter motor : oe, Lives, ‘Type Seo ea ‘Md5G, 12-volt (solenoid-operated), Lock torque (ter I voltage Gf, current 900 amps.) .. 325 Ib, ft, (4°49 kg. im.) ‘Torque (terminal voltage 8-8, current $10 amps.) 15-5 1b. ft. (2:14 kee. m.) at £,000 r.p.m, ( Rati eS ae ie Lodge DD2/3 or Champion AG. Heater plug resistance Lodge Type . ty OE I, WHEELS AND TYRES Wheels Type é See a Ventilated ise. Wheel nut torque figure. By cel tae 100 Ib. ft (138 kg. m.). Size ‘Standard is gas 2 50x16, Alternative =. eat oe 6x15, Fixing. Dee tem os Sestud, ' ‘Tyre sizes and pressures | NOTE.—The following pressures are for normal road and cross-country conditions 6-00-16 tyres tee eee (Eront) 25 1b/sq. in. (1-76 ke fom. (Rear) 30 bsg. in. 2:11 ke.fera.4). | 65016 tyres ~ + Eront) 25 Ib,/eq. in. (1-76 kg fem.) | (Rear) 25 Ib/sq. in. (176 kev, i Podand 75016 tyres... ees CEront 20 b/s. in. (4) fem, 2, (Rear) 20 t/q. in. (141 kg. fom.) Govcral Data 8 *GENERAL DATA—conrinued NOTR.—The following presses roused whe lon exconling $60 (254K) 60) and 65016 tyres T9016 tyres I-16 tyres PRINCIPAL DIMENSIONS: Length overall: (G4M10) (GaMs) Width overall : Height overall (unladen) Ground clearance... CAPACITIES Diesel sump (including fiery Petrol sump (including filter! Filter capacity Cooling system (excluding heater) Main, gearbox eS Transfer gearbox : Front ale Front hub and swivel housing Rear anie Steering-box Fuel tank Air cleaner TORQUE WRENCH SETTINGS Petrol models Cyfinder head nuts Big-end bolts Main bearing nuts Flywheel bolts Gudgeon pin clamp bolts Diesel models Cylinder head nuts . Bigeend and flywheel bolts. Main bearing nuts Fuel injector securing nuts. Fuel injector nozzle mut Fuel injection pump Governor control cover stud Governor control cover stud nut Governor control bracket sorew Governor drive shaft screw Governor vent screw body Distributor rotor serew ‘Cam advance screw Drive piate serew a Transfer pump rotor. End plate set belt Hydraulic head locating fisting c carried in the rear ofthe vehicle. (Front) 25 1bJoq. in. (1-76 kg.fom. (Bear) 29 Iba, in. (241 ke.fem2). (Front) 20 1b/3q. in. (41 kg.jem.. (Reur) 39 [b/sa. In. G11 ke. fem. (Eront) 20 1b./5q. in. (I-41 ee fem (Rear) 25 Ib sq. im. (176 kg. fem.) 163} in, (4-162 mp 66) in, (1-695 in), 74} in. 0-886 in). 8g in. C2 9 pins (5:25 lites) 1g pints (6:38 litres). LE pints (7 litre) 21 pints (12 litres) 4 pints (22 litres. 34 pints (2-9 litces), 3 pints (1-73 litres). 1 pnt (-57 litre) 2+ pints tS litres). 4 pint 5 lite), 12 gallons (54-5 litres). 1 pints (83 litre} 55 Ib. ft. (7-60 ke. m. 50 Tb, ft. (6-91 ke. 80 Ib, ft (11-06 ks am). 50th. ft (6-91 kgm. 35 Ib, f. (4-84 kg. ma 75 Ib, (1037 ke. me) ‘50 Ib. fe (6-91 ke. m3. 80 Mb. fe (11-96 kes mi) 12 Ib (17 kg.) 30Ib, 1. (700 kg. my (60th. in. (469 kg. m), 40 Tb in. (46 kg. m). 21 Ib, in. (24 kg. m). 285 Ih. in. G3 ke. mo) 65 Ib, ia, (75 kgm. 28 Ib. in. (32 kgm). 300 tb. in (3-45 kgm. 160 Mb. in, (1-85 kg. mi.) 65 Ih. in. (75 ke, m.)e 45 Ib in, (-52 ke, m.)e 350 tb. in. (4-05 kg. m.). General DataGENERAL DATA~—cont nued Advance unit housing cap nut 10 1b. in. (1-25 kg m Advance unit housing st 60 Ib, in. (69 kg. rm.) Advance unit housing spring cap and end plug 250 Ib, in, (2:9 ke. m. Hydruulie head locking sccew 170 1b. in, (1.96 kg. m High-pressure outlet banjo pipe bolts 270 tb. in, (1 kg. m) Control and “shut-off” lever muts 30 Ib. in. (34 Fuel inlet connection 360 Ib. in, (4 Back leakage connection 140 tb. ja. (I General Data 10GENERAL INFORMATION CONTROLS AND INSTRUMENTS: Gear change lever ‘The gear change lever is centrally offset and comes readily to hand. The positions io which the lever is to be moved. to obtain the gears are shown in the illustrations. Lift the lever to engage reverse. Pedal controls ‘The pedals are arranged in the orthodox positions—namely, the clutch pedal, brake pedal. and accelerator pedal, reading from left co sight Hand brake A pull-up-type lever protrudes from under the front seat and operates mechanically on the rear wheels only Choke contral (petrol engine) Pull out the control marked *C’ to its limit when stacting the en the engine Nill pun without its use ine from cold. Push in the control fully as soon as 1, Ventilator conte 5 Cluteh pada 2 icstor contr 9 Drake pedal LG 10 Accelerator peal. 4 Boarinhecl-ive indicator plate, 1 Headlaang dip site 3. Four-mheel-drive (low ratio) lever. 12 Hoen button. 6 Foutemheelarive (high ratio) leer 1, Windscreen wiper contra 7. Hand brake, 14 Ventiaior contr Tenition master and starter switeh (petrol models} ‘The switch is operated by a removable key, When the key is turned in a clockwise ditection te the first position the battery and dynamo are brought into cireuit, Further movement in the same direction will operate the starter motor. Release the key immediately tha engine starts, If the enging fails to start first time wait witil it has come to rest before operating the starter switch again. The switch must not be left on when the engine is not running or the battery wll discharge itself through the coil should the contact breaker paints be closed Master, hester plug, and starter switeh (diesel models) For normal starting depress fully the accelerator pedal, turn the key clockwise to the First stop (which turns on the electric auxiliaries), then further movement in the same diraction to connect the starter. Release the accelerator “Yi and the key immediately the engine fires For gold starting turn the key anti-clockwise to the first stop and hold it in this position for a period of between 15 and 30 seconds to allow the heaier plugs to warm up, depress fully the accelerator pedal, then move the key to theGENERAL INFORMATION—contiaued Second stop to operate the starter, Release the accelerater pedal and the key immediately the cngine fires. Turn th. key clockwise to the first stop to switch on the auxiliaries, ngine stop control (diesel models) Pull the control knob fully out to cut off the fuel supply to the injection pump. when the engine wil cease firing, Return the knob to the fully closed position before operating the stacter control. Lamps switch Moye the switch downwards to the hallway position to bring the sidelamps and the tail lamps into operation ‘and into the fully down position for the headlamps, The panel lamps are also illuminated when the switch isin operation, Four-srhcel-drive (low ratio) lever Located on the sight sid and backwards to engage rea of the gearbox cover. Move the lever forwa -avheel drive. The central posit to en neutral and disengages 1 wheel drive (low ratio) irive to all wheels The controls —L.H.D. models 1. Yenttata at 8. Chueh ged. 2. Dimi indintor contol 9) Brake ped 3. Gaines 10. Aoeskrtor peda ( 1, Bomrvhes vie inate plat 11, Heenan ip vik, 5. Fomeunel drive (lw ret) lve 12. Hern button, 8. oarsheat drive (aah tive 15. Windsereen wiper cont 7 Hand bake 14. Ventator soot Four-wheel-drive (high ratio} lever ‘This is 2 two-position lever located immediately to the right of the low levers backwards to engage four-wh to its neutral position. tio lever. Move both highs and lowsratio drive in high ratio, To regain rear-wheel drive move the high-ratio lever forwards Direction indicators To operate, move the switch to the left or right, according to whichever indicator is required. A warning light flashes green for as long as the indicators are in use ‘Ae control A-supply of unheated air can be acimitted to the body interior for ventilation purposes by Lifting the lever mounted centrally just above the instrument panel. Windsexcen wiper ‘The windscreen wiper is started hy pulling out tho handlo and tuening it to the right to disengage it frem the swit ‘Then move the switeh to the leit, To stop the wiper move the switeh to the right, pull out the handle to disengage tite wiper blade from the gears, and turn the end of the handle into the top of the switch control Geaztal Information 2 yeGENERAL INFORMATIONGENERAL INFORMATION —continued Rearevhee! drive Cis rato). Fenr-wheel drive hich ratio), ourswhel drive (om ria), Fronts drive (high rat) ‘Neutral poston for power takewo. at Fo 3. 4 c 5 The for-wheetdrire lever positions aT a 4 6 06 o& Mounted on the right-hand side of the steer column and ean be operated when the ignition switch is off switch ‘Located in the horn button body and consists of a stall twe-position lever for dipping the headlight beams. (Ol pressure gauge "The gauge indicates the pressure (in Ib/sq. in.) of oil being delivered by the pamp. The gauge shoukl register within 30 seconds of starting the engine, Pucl gauge ‘The gauge will indicate the quantity of fuel in the tank when the ignition’master switeh is operated. Water temperature gange The gauge will indicate the temperature of the cooling water in the engine when the ignition/master switch is operated. ‘Speedometer ‘The meter indicates the speed of the vehicle and the total distance travelled. Panel lamp “The interior Lamp is opecated by a tozale switch positioned on the feseia panel and will only operate when the side and tail lamps are switched on. Tgnition/master swite, flashing indicator, and main-bear warning lamps ‘The ignition/master swites, ashing indicator, and mais-beam warning lamps are positioned in the base of the spcedometer ial. ‘The ignition/iaster switch wacniag lamp glows ved when switched on, but will go out to indicate that the dynamo js charging as the engine speed is increased. ‘While the flashing unit is operating, the warning lamp glows green intermittently. ‘Phe main-beam warning lamp glows blue waen the headlamp beams are raised and will go out when they are lowered i = | elas J, b doo Daun ® ‘The insirwnents—RH.D. models The instruments—L.H.D. mode 1, anal tcp ewe 7. Pont pope 1. Pel lamp sith 2. Bus gauge, 2. Speedometer, 4 Dicccion indicator warning 2 Spoofometer. 4. Diretion iadiotor waming fe Temperate snege. Tih 2. Temperature gauge. Nght AL Gil pressure cause. 2. No-sarg warning ht ‘Olt presure gauge. 9, -Nocharge wamin lig. S| Mam tgningaviten, 10, Main-beurywaraing gh 3. Nias aaingawich. 10. Main-hoam warning aS. © Ignilon orauster switch, 11. Choke or stop contol Ignition or maser sion. 11, Choke or stop conzrol General Tafematlon 3GENERAL INFORMA Chassis muonher. Stamped on a plate on the chests Fads momrber. Stamped on a plese nrowsted on the heel from moumuneg reatiator cowl aujiae ous 9 the engine GENERAL Windscreen (soft top movils) If Jesied, the windscreen headed bolts at each end of the windsere rubber rest on the bonnet. sd forward to lie horizoncally on cop of thy bonnet. Simply releuse the wing and lower it until the rest in the centre of the windscreen engages in the Fucl filter ‘The fuel tank is positioned at the side uf the velbele and iy sealed by a.cap will a bayonettype lining. Unserew the cap in an anti-clockwise dirzetion to zemove it. Considerable loss of fuel ean occur as a result of filling the fuel tare ‘until the fuel is visible in the (ill tube, [this is done and ths vehicle is fet in the sun, expansion dug to leat will eause leakage, sith consequent loss of and dang en filling up therefore: (1) Avoid filling the taak wot che fuel is visible in the filler tube 2) IP ce tank is inadvertently overtiied, take eure 10 park the vehieke in the shade and with the filler as high as possible. ze From exposed fucl LOCATION OF MAJOR COMPONENT SERIAL NUMBERS The major components of the vehicle have serial numbers. When i communication with your Dealer always uote the chassis and engine wumbers. The registration number is of no assistance and is mot required. The en: umber is stamped on a plate fixed to the side of the cylinder hlock. Other major compenents have their serial numbers stamped upon them and their locations are showa ia the illustrations, CLAIMS UNDER WARRANTY ~ hi butor or Dever, or, when this is not possible, 19 the usarast Distributor or Dealer, in name and address mitted to the supplying Dist ming them of the Vendor's ‘ur the replacement of material ar parts under Warranty must always be « PRESERVATIVE ON EXPORT ¥ENICLES To cemove the hard shim preservutise from the extern plited puris a cloth dipped in a solution ef equal parts of ‘white spirit and petrol should be used. Take care to keep this solvent from anything other than the plated componcats IDENTIFICATION OF UNIFIED SCREW THREADS The general standardization of Unified screw threads mahes it necessary to idemify all nuts, bolts, and set screws with these threads in order to ensure (heir being matched with correspondingly threaded components and the fitting of correct replacements, Identification has been stangardized and is effect Nuts. By a circular groove turned on the end fix exngon. Bolts and vet serens. By a ciscular slepression vurned on the heal or by connected circles stamped on one flat of the hexagon in the following manner of the svt or by connected cirgles stamped on one flat of the General Information $GENERAL INFORMATION—contiaved Wheel stad nats. By a notch cut in all comers of the hexagon It is of the utmost importance thut any auts, bolts, or set screws marked with the above identifications arc used only im conjunction with associated components having Unified threads and that anly replacement parts with Unilied threads are used, as these are aol interchangeable with: Whitworth, B.S.F.. ot Metric teal fhangeath American National Pine (A..F) thread for all pra ad is, however with ‘Spamners. Tt is to be noted that sll ALN. Unified-threaded nuts and hexagon-headed bolts are made to the standard American hexagon sizes and that spanners of the appropriate sire must ke used whea tighte them. KEY TO SPANNER SIZES (Nominal widths botweon jaws) For A.N.F, screws and nuts | 440 wta2 | 1920 For Unified screws 440 1132 | 321} aE a8 a For Unified nuts (normal 440, For Unified nuts (heavy) ms ‘NOTE in ti ofthe bolt Wwe this cours te Spann ia fe the ize ofthe hexagon forthe at is diferet from that on im heavy type ote above ta. PART NAME ALTERNATIVES Pari Neon Alternatives Fogine Gudgeon pin Piston pin, Small-ead pin, Wrist pin, Seraper sin; Oil eontrol ring. Core plug Expansion plug. Welch plug. Seal Oil sump Oil pan, Oi reservoir Controls Mixture contro! Choke. Strangler. ‘Gearbox Gear lever Shift lever, Change speed fork Shift fork. Selector fork. First motion shaft Clutch shaft. First reduction pinion. Main drive pinion. Drive gear Layshaft Countershatt, Axle Crown wheel Ring gear. Spiral drive gear. Bevel pinion Small pinion. Spiral drive pinion. 2 "UT" bolts Spring clips Axle shaft Half-shafl, Hub driving shaft. Jack driving shat. Diflerential gear Suan wheel Differentie| pinion Planet wheel Steering Swivel pin Pivot pin. Stoering pin. King pin. Stub axle Swivel axle Cross-tube, Side-tube. Steering connecting red. Electrical Dynamo Generator Control box Voltage regulater, Cut-put. Voltage contro: Exhaust Silencer Muir Body Bonnet Hood. Wing Mudguard, Fender. Genera! Information 6MAINTENANCE ATTENTIONS PERIODIC SERVICING—rebicles in use ‘The servicing instructions g ‘concise manner the attentions required te maintain the velicle in aw elf and climate. E attentions age give suit local conditions. Where the actual stead of a “distance” basis and it must therefore be me climatic or aperating conditions may. however, necessitate alt per y f cw the discretion of upen fen in the table following have been tabulated in order to show in a clearly arranzed and condition under normal conditions of work tions to the intervals at which some of the ors on the spot t© vary these intervals 19 stance rin in a gikea period is small it muy be advisable to apply the instructions on a ‘thine’ When checking nuts which are split-pinned or sccussd by tab washers examine for signs of movement or lexkage before attempting to tighten them with a spanner. Only hand pressure ‘ould be used whea chek 2 for tishmness swith a spanner, and a gorgue wrench used when culled for in the insirections. Du nut nvertighten. Weekly service Check the oil level in the e necessary. Cheok the water level in the radiator, and top up if necessary. ‘Cheok the battery electrolyte level, and fill up if aecessary. ‘Check the tyre pressures, and correct if necessary. ne sump, and top up if 3,000 miles (4800 ken.) oF 180 hours service Diesel models Drain and clean the external oil filter. fit a new element, and reilll with new cil. Diesel ened petrol modets Drain the engine surap and refil with new oil Check the oil level in che main and transfer gearboxes, front and rear axtes, swivel housings, and steering-hox, ‘and top up if necessary. ‘Check the fan belt tension, and adjust if necessary’ Check the fluid level in the clutch reservoir, aid top up if necessary. Check the braking system for any visible damage ot leaks, and adjust the brakes if necessary. Chicck the brake fluid level in the reservoir, and top up if neces sary. Lubricate the track-rod and draglink joints. Lubricate the propeller shaft universal joinis and splines Lubricate the accelerator linkage Lubrigate the hand brake and pedal linkages. Lubricate the four-wheel-drive lever linkages Change the road wheels round to regularize tyre wear. 6,000 miles (9600 kan.) oF 300 hows service ‘Carry out the 3,000 miles (4800 km.) o 150 hours service, with the following additions: Petsot madels Renew the external oil filter element Clean the carburetter, and reset the slow-running adjustment. Examine and elean the distributor points, and reset the sap Check the operation and hubricate the distributor mechanism, and reset the ignition timing if necessary. ‘Clean the sparking plugs and reset the saps, Diese! models Renew the main fuol filter element, Diesel and perro! models Drain the main aud teansfer gearboxes and front and ear ales, and reall with new oil Drain and clean the oil-bath-type air cleaner, aad refill with new oil Lubricate the dynamo bearing. Check the valve to cocker clearances, and reset if necessary Check the front wheel alignment and steering connec- tions, and adjust if necessary. Check ‘and tighten all nuts on the engine, searboxes, front and rear avle ‘U" bolts, universal joints, spring shaeklos, fel tank, exhaust pips, and spare wheel carrier Tighten serows on door locks, catches. striker plates, ‘aud hinges and lubvieate as necessary Check the specific gravity of che battery elecirolyte, and top up if necessary. Roadtest the vehicle and report 9.900 miles (14400 km.) oF 450 hours service ‘Carry out the 3,090 miles (4800 lem.) oF 150 hours service. 12,000 miles (19200 kan.) or 600 hours service ‘Carry out ihe 6,000 miles (9600 km.) or 300 hours service with the following additions: Peerol models Renew the sparking plugs. Diese! and petrol models Drain, remove. and clean out the engine sump and exiernal oil filter, Clean the oil pump strainer and the erankease intecnally, Refit the sump und filter and refill with new oil. Lubrigate the water pump bearing, Check all nub bearings for play. Check the steering gear for play, and adjust if necessary. Check the headlamp beam setting, and adjust ifnecessary. Maintenance Aticatlons 1MAINTENANCE ATTENTIONS 15,000 miles (24000 km.) Carry out the 3,000 miles (4800 km.) or 150 hows service 18,000 miles (28800 km.) or 900 hours service, Carry ow the 6,000 miles (9600 km.) or 340 hours service continued 21,000 mites (33600 km.) oF Uy Carry out the 3,000 miles (4800 km.) or 150 bo Inours service 224,000 milles (38400 km.) or 1,200 les (19200 kam.) er 600 hours Carry out the 12,000If rnieP SECTION A # Cd THE PETROL ENGINE Adjustments in the vehi Cylinder tn Aas Decarbonizing Als Descriptio Al Engine—removing and repla A3 External oil fite AG Flywheel and housing—removing and replacing A28 Flywheel ing Aso AA Lubrication systema ‘Main bearings and ceankshaft—removing and replacing M removing and replacing Ato Oi pressure rel e Ad Oil pump Dismantling and z As Removing and replacing AT Oil sump—temav replacing AS Piston and connecting rod Dismantling and reassembling Az Removing and replacing ~ Aal Push-rod: ving and replacing AL Rocker busher—removing and replacing ‘aud aft-—removing ane. replacia) AA fagnosis chart ASL ice tools End of Section Als AlT A20 — . a ng. and replaci AlA Section Ad DESCRI TION ‘The four-cylinder internal-combustion engine used in this velicle 15 supported on the frame at lour points: by two brackets on the engine front plate and boited nd by 2 bracket on the gearbox extension and belted 1¢ the cross-mensber which passes under the gearbox. The engine mot Ingubsted at the front and rear Lo eushien wibrations The eylinder block and erankease are cast in one pieee for rigidity. The eylinders are waterjackeied the full length of the hore 10 provide efficient cooking The cylinder head, which earries the valves und rocker ‘seat, 8 secured to the cylinder block by I studs and nuts and is completely water-jacketed. ‘The water pump is located on the front of the cylinder block by three studs andl is driven by a *V" belt from the crankshaft ‘The camshaft is located ia the crankcase and is dive ‘by a duplex roller chain from the erankshaft. A. symhotie rubber ring is fitted 10 the camshaft chain wheel, which ensures quiet running. ‘The crankshaft is supported by three main bearings, ‘whieh are renewable Downdraught carburation with hot-spot vaporizer induction is used, feeding all four cylinders through single manifold whieh is secured with the exhaust mani- fold to the left-hand side of the eylinder head Crankease ventilation is provided by n pipe secured to the tappet cover on the leftehand side of the crankcase. ‘A second pipe connects from the vaive gear cover t0 the air sleaner. The oil supply is contained in @ pressed-stecl sump, and a submerged rotor-type purmp, driven from the cam- shaft by an inclined shaft, draws oil from the sump through a strainer and delivers it through a rencwable- element-type pressure filter on the right-hand side of the engine. From the filter oil is forced through drilled assuges 10 the eumshaft and crankshaft bearings, the timing chain, and the overhead-valve rocker shaft. Any eccess oil is hy-passed hack to the sump through a release valve situated behind the extermal oil filter in the cramk- ease. @ the [ont crass-member Section A.2 ADJUSTMENTS IN THE VEHICLE ‘The purpase of the following adjustments is to mai tain the performance of the cagine at its maximum and consists of a series of cleaning, inspecting, and adjusting operations. The operations listed below are essential items of maintenance which may have to be accomplished. during normal service with the engine in the vehicle Test the compression of each cylinder. If a com- pression gauge is not available a simple method is ta, remove three sparking plugs, Jeaving the remaining plug in the eylinder being tested. A general indication of the a2 will be cbtained when the engine is cranked two revelusions, nevally andl Iubricate at the resem ceompression by band through at Ie Clean the engine mended Adjust the fan belt tension ¢see Section €). Remoxe the valve gear cover and check the cylinder fread nuls to the recommended torque set Check and adjust the valve to cocker Section 4.20), Make a vistial inspection for evid springs or scored value stems, Remove snd clean che sparking plugs. Examin. insulation for dawiase. Ensure that the correct type of plug is being used. Adjust the points gup. Test the plugs and renew any found to be unlit for service, using new gaskets. Check the high-tension cables Tor fractures amd deterioration before refitting (see Section N). Remove the distribucor head cover, clean, and examine it for cracks and burned conlaels. Inspect the contact poimis to decermine whether new points are needed or Cleaning and adjusting ate necessary. Ensure that the carbon brush contacts the roter arm and that the capacitor terminals are clean and securely tightened. Check the inition timing (see Section Bh. Drain, clean, and refil the air cleaner (see Seetion D). Ensure that the fuel system is operating elficiently and clean all fliers in the system. Chock the carburetter manifold flange gasket for evidence of leakage, and adjust the earbueetter if necessary (see Section Di. \ee of cracked valve Section A.3 REMOVING AND REPLACING THE ENGINE First method Remove the engine, gearbox, and transfer box as a unit by adopting the following procedure, Drain the cooling system by opening the two taps, fone on the side of the cylinder black and the other at the bate of the radiator. Rolease the radiator top and bottom hoses. Disconnect the battery. Remove the blanking platc from the top of the radiator cowl leg, taking out the 10 securing screws. The electrical harness whieh runs across the top of the plate can be moved to one side after disconnecting it at the snap connectors. Take out four set pins (two each side) from the radiator mounting frame, Lift out the radiator, Remove the front grille by taking out the 10 securing set pins (duree on each side and ovo exeh side of the front apron}, Release the clips which secure the air intake hoses to the air cleaner. Take out the set pin from one side of the air cleaner sccuring strap and lift the air cleaner out of the vehicle Disconnset the exhaust pipe from the manifold anc release the to securing points far the exhaust pipe; which are siuated below dhe chassis, one on the down pipe and one on the silencer. Remove the exhaust.