Downloaded from www.Manualslib.com manuals search engine OPERATION No MA. 451-O : Uwckirrg the hrflkv rov,~o,rrnts Op. MA. 451.0 1
CHECKING THE RUN-OUT OF THE BRAKE DISC -
FRONT BRAKES REAR BRAKES 2
E Equipment required :
,,, - 1 universal dial gauge bracket ( 2041-T or 5602-T )
1 dial gauge 2437-T
3 screws, hex. head
6 = 12 mm, thread pitch 1.25, length = 30 mm )
( Ex Crown wheel securing screw on (< D a)
vehicles ). Method :
1. Raise vehicle and assemble equipment as shown
above.
Tighten the three screws (
- ) to opproximo
My 70 mN i 7 m.kq ) ( 50 l/2 ft.lh ).
2. .Sl,l did g”“g” rod RS pwp<‘il~cl,l171 ns p”ssibl<~
10 &SC iorr. The run-out thus registered must not exceed 0.2 mm.
If this condition cannot be satisfied the disc must
be chanqed.
Downloaded from www.Manualslib.com manuals search engine Op. MA. 453-O 1
I. BLEEDING THE BRAKES ON SALOON AND ESTATE VEHICLES ( 9/1976- )
A. FRONT BRAKE BLEEDING
NOTE : To avoid emulsifying the fluid
and the
consequent formation of air-pocket in the system,
the circuit should not be under pressure when this
operation is carried out.
1. Release pressure in circuits :
a) Raise front of vehicle (wheels free 1.
b) Slacken pressure regulator bleed screw ( 1 ).
Remove front wheels.
c ) Place CI transparent tube over each bleed
screw (2 ) with its oiher end in CI clean
container.
d) Hold r/on,,,
brake pdnl ar,d loose,, blvcrl
*cr(Iws (2). 2. Bleeding :
(I 1 Start engin’e (idling speed 1 and maintain brake
pedal fully depressed.
b) Tighten pressure regulator bleed screw and
allow fluid to flow until bleed tubes ore
free of air bubbles.
Then tighten bleed screws (2 ).
c) Release broke pedal and remove bleed tubes.
Check the bleed screws for .leaks by depres-
sing brake pedal to fullest extent.
Stop engine.
Fit rubber protectors over the bleed screws.
d 1 Replace front wheels and lower vehicle to
the ground.
B. REAR BRAKE BLEEDING
3. Release pressure in circuits
a) Set monuol height control to lou posi/iou.
b 1 Slacken pressure regulator bleed screw ( 1 )
c) Wait until vehicle has reoched.its lowest
point.
Raise rear of vehicles (wheels free )
Remove lower rear wheel panels and rear
wheels.
d 1 Set manual height control to
hifih positior,
e ) Place Q transparent tube over each bleed
screw with its other end in (I cl&n container.
f ) Open bleed screws (3 ) and depress broke
pedal to fullest extent. 4. Bleeding :
(I) Tighten regulator bleed screw ( 1 1.
Slur/ w?@nr, holding broke pedal depressed.
b) Allow fluid to flow until no bubbles appear
in tube.
Then tighten the bleed screws.
Release brake pedal.
c ) Remove tubes. Check the bleed screws for
leaks by depressing the bloke pedal to
fullest extent. I
Fit rubber protectors.
Stop engine.
5. Refit rear wheels and detachable panels.
Lower vehicle to ground.
Downloaded from www.Manualslib.com manuals search engine 2 OPERATION N” MA. 453-O : (./ ‘cc ,,,g md ndjaslisg I/w hsdrmlir hrnkr rev/m/
k.
II. BLEEDING THE BRAKES ON ESTA ,TE VEHICLES (- 0 ,970 )
A. BLEEDING THE FRONT BRAKES AND THE AIR
CHAMBER ( 1)
NOTE
This bleeding must be carried out with no
pressure in the system
in order to avoid any emul-
sifying of the liquid. and consequently the possible
formation of air bubbles in the system.
1. Release pressure in the system :
a 1 Raise front of vehicle ( wheels free ).
b ) Slacken release screw (3 ) on $ressure requlo-
tor. Remove the front wheels.
c 1 Place on each bleed screw ( 4 1 a transparent
tube wi!h its other end in a clean container
d ) ,Mnir,lnh, brnk L p&d /u//y d<~pwss,~d. and
slacken bleed screws (4 ).
e) Remove air chamber ( 1). Place a transparent
tube on the end of pipe (2 ).
2.
Bleed the br.kes :
a) S/or/ ~v,gir,c,. C id/ivg spevd I md vrnialni,r
hrnk L firdnl. tullr d,~pwss<~d
b) Tighten release screw on pressure regulator.
and let fluid flow until there are no more air
bubbles in the bleed tubes.
Then tighten the bleed screws.
c) Release broke pedo1, and remove bleed tubes.
d) I:;/ nir rhnmhrr ( I ) nltcr hnr~htg /dorm i/
Ibrouph I, i/h Nmp IPSS ?,I nir.
e ) Check bleed screws and air chamber ( 1) are
properly sealed
by fully depressing brake pedal.
Stop engine. Place rubber protective caps over
bleed screws.
f 1 Fit front wheels and lower vehicle to the ground
B. BLEEDING THE REAR BRAKES
3.
Bleed the rear brakes :
a 1 Raise rear of vehicle ( wheels free ).
Remove removable panels and rear wheels.
b) Place manual height control lever in c high
posi~im H ( Release screw on pressure regula-
tor tightened 1.
c) Place on each bleed screw ( 5) a transparent
tube with its other end in a clean container.
Slacken bleed screws (5).
d) nlfliuiniv broke pcdfll ~yrrlly depwssvd. ar,d s/or,
vspiuv C idiivg sprcd ).
e) Let fluid flow until it is free of air bubbles.
Then tighten bleed screws.
Release brake pedal.
f ) Remove bleed tubes.
Check bleed screws are propeily sealed by
fully depressing broke pedal.
Fit rubber protective cops.
Stop engine.
4. Fit rear wheels and removable panels
Lower vehicle to the ground.
Downloaded from www.Manualslib.com manuals search engine OPERATION No MA. 453=0 : Ch J k’ ( c zng and adjjusfing thr hydraulk brake rontrol Op. MA. 453-O 3
III. CHECKING BRAKE PEDAL FREE PLAY
1 st Fitting 2nd Fitting
1 5 111 (I I /‘)7-t __t i%
+ 1. Turn screw ( 1 ) to obtain a clearance of
s
E
(( J )) ~~ 0.05 to 3 mm
-ii Tighten lock-nut ( 2 ).
2 2. Ch k’ ec Ing operation of brake pedal :
a) Release pressure in system.
Set manual height control to /or! /~~.s\‘itio~/
Slacken pressure regulator bleed screw.
( I/ Ill<, I <~/liClC~ is /ill1 rl i, ill, N I~tYlk~~ n~-rllrlll,Inlo,~. nc/un/1 II?<, /I< r/al.
hnke nr c111uu/n/0,. ).
b) Depress pedal three or four times to move the control slide valve to the end of its stroke, and ensure that
pedal returns freely to its stop.
There should be no variation of clearance o J )) as initially set.
Tighten pressure regulator bleed screw.
IV. ADJUSTING THE STOPLAMP SWITCH
1.
Check adjustment of free play on brake pedal ( see above ).
2. Adiusting the stoplamp
The stoplamps must light as soon as the pedal contacts the brake valve.
Bend support plate u a )) of the switch in order to achieve this condition.
Downloaded from www.Manualslib.com manuals search engine OPERATION No MA. 454-O : Lhcckiu~ avd adjnsfbrR fhe bandbrake op. MA. 454-u I CHECKING AND ADJUSTING THE HANDBRAKE
1.
Raise front of vehicle ( wheels free ).
Remove front wheels.
Release handbrake lever to maximum extent 2. Adjust eccentrics :
a) Remove adjustment nuts ( 1 ) and lock-nuts (2.)
for handbrake cables.
b ) O,,,‘varh hmokt~ ,,rzit :
Slacken SCI~WS (4) of eccentrics ( 6 ). Ensure
With spanner 6501-T turn eccentrics as shown f rrpu,ards ) until the pads just contact the disc
at point of maximum run-out.
Tighten screws (4) from 6 to 6.5 daNm (43 l/2
to 47 ft.lb ).
Check correct contact of pads.
Screw down stop SCI~W (3) until it contacts
the brake unit housing ( tighfrn its lock EN! 1, 3. Adjusting hondbrake control cables :
, On rnrh hrnkc ,,,, if:
Ensure
Pull alfcmnf~~iy on each threaded end-piece (7 )
ond measure its protrusion (< c 1).
.Example : Protrusion on right-hand side = 30 mm
Protrusion on left-hand side = 26mm Difference in length of cable must remain the
some after adiuitment.
Downloaded from www.Manualslib.com manuals search engine OPERATION No MA. 454-O : Ch ec tzg and a&sting the handbrakc k’
Screw down cable adjusting nut (2) against
lever ( 1) Tighten lock nut ( 3) to 1.5 doNm ( llft.lb)
4. Checking tie handbrake :
Operate handbrake lever several times.
Check that adjustment does not change and that
locking system operates satisfactorily.
5. Refit front wheels : Tighten screws from 6 to 8 daNm ( 43 l/2,
ta 58 ft.lb ).
Lower the vehicle to the ground.
Downloaded from www.Manualslib.com manuals search engine OPERATION No MA. 510-00 : \m//l‘!yc~tl/ <‘,/I 0 t Ih<’ <‘It,< Ir.itnl iusrtlllnliritt Op. MA. 510-00 3
f 0 lO7i-l,‘1975 )
DESCRIPTION OF THE COMPONENTS
!ep. Description and Position Rep. ‘D escription and Position
1
Right hand sidelamp ...... 74 51
Flasher unit .. ....... 21
Front right hand direction indicator ..... 21 52 Lighting and starter switch .... .4 8’44- 61
2 Right-hand headlamp Main beam .. 78 5.3
76 54 Petrol gauge rheostat ........ 25
Dipped beam
Right hand window winder control switch
3 Right~hand horn ............ 42
( O/)liWlNl J ................. 51
4 Left-hand horn ...
41 55 Heating control illumination f ~///io~n/) .. 68
5 Left-hand headlamp : Main beam ....... 77 56
Left hand window winder switch ( O/JI~OII~/~~~
Dipped beam ...... 75 57
Heated rear window switch Op/io~nl j ...... 14
6 Front left-hand direction indicator ... 16 58
Lightinq switch unit ............. ........... 72
Front left hand sidelamp ................. 69
Speedometer and tachometer lighting
8 Electric fan thermal switch .................. 59
rheostat ....... ...... .................... 28 10
Electric fan .......
58 59 Instrument panel : 11
Starter ...... ... .............. .......... 3
Thermal voltmeter and illumination .. 26-28 12
Alternator ............................ ........ 5 13 Petrol gauge and illumination ............ 25-69
Ignition coil ... ......... .............. 61 14
Speedometer and tachometer lighting 28
High tension sensor ....................... 64
Clock and clock illumination ....... 1667 15
Compressor for horn ............ ..... ...... 43
Heated rear window warning lamp ....... 15 16
Compressor relay ................... ..... 43
Headlamp dipped beam warning lamp ... 75 17
Battery ............. .... .. 1
Brake pad wear warning lamp .......... 27 18
Voltage regulator ......................... 6
Oil temperature warning lamp ............ 35
19
HT sensor for No. 1 cylinder ........... 64
Coolant temperature warning lamp ....... 29 20
Distributor ..................... ...........
61 Emergency stop warning lamps 32” 34
21
Windscreen washer pump ............. 36
Hydraulic pressure warning lamp ...... 31 22
Plug for diagnostic operations ............. .65
Warning lamp for hazard warning.. ...... 17 23
Engine oil pressure switch .............. .. 34
Sidelamp warning lamp ................... 70 24
Idle cut-off ....................... .60
Direction indicators warning lamp ........... 23 25
Engine oil temperature switch ........... 35
Headlamp main beam warning lamp ... 77 26
Enqine coolant temp. switch ... 30 60 Left-hand control panel : 27
Top dead centre sensor ........................ 64 Direction indicator and hazard warning 19 28
Reversing lamp switch ........................ 8
- Horns .................................... 41 30
Window winder control relay( Optior~nl ) .. ..4 9
Windscreen wiper motor ............... 38-39 31
Heating relay ............ ..................... 45
- Windscreen washer pump .......... . .......... 37 32
Electric fan relay ................................ 58 61
Rear right-hand lamp cluster 33
Front right-hand brake unit ................. 28
- Rear lamp ............................................... 73 34
Windscre,en wiper motor ........................ 38
- Stoplamp ............. .....
............ 53
35
Blower motor ............ .............................. 45
Direction indicator ................................... 19 36
Hydraulic pressure switch ...................... . 32
- Reversing lamp ..................................... 9 37
Stoplamp switch.. ......................................... 53 62
Boot lamp ................................................. 12 38
Fuse boxes ..... 8-44-45-49-69-72 63 Rear window heating element ................... 14 39
Front left-hand brake unit .......................... 26 64
Right-hand number plate lamp ................. 72 41
Front right-hand door switch ................... 11 65
Left-hand number plate lamp ................... 70 42
Right-hand window winder motor f Optiollal) 51 66
Boot lamp switch ........................................ 12 43 Glove box
lamp ...................................... 51 67 Rear left-hand .lamp cluster 44
Front left-hand door switch ........ .......... 10 - Rear lamp ................................................ 71 45
Left-hand window winder motor (Oplio~fll) 47 s Stoplamp ........................................... 52 46
Interior lamp ................................................. 10
- Direction indicator lamp ..................... 18 47
Cigar lighter and illumination ............... .13-67
- Reversing lamp .................................... 8 48
Accessory plug ..... ... .......................... .... 50
49
Ashtray illumination ,., ... ................ 66 DESCRIPTION OF THE WIRING HARNESS
lot marked :
Front harness co Compressor harness AR
Rear harness C Boot harness
M Engine harness PC
Boot lid harness LG
Window operation D Fault finding harness ( Diagnostic) TB
Instrument panel harness FV Flying lead
Downloaded from www.Manualslib.com manuals search engine TABLE OF FUSES
Supply to
eater unit relay Fuse
Circuits protected
Rating Colour
16 Amps Mauve Heater unit
S toplamps
Accessory terminal
Glove box lightinq
Positive terminal
of battery u + )) 16 Amps Red
E Direction indicators
Ignition Windscreen wipers and washers
switch Horns
Heater relay windinq
Window-winder relay winding
Rheostat -speedometer lighting
Warning lamp panel ( Battery
meter ( Thermal voltmeter-- Brake pad wear warning
lamp - Fuel gauge - Oil pressure warning lamp -
Hydraulic fluid pressure warning lamp-Water temp.
warning lamp )
16 Amps Green Interior lamp
Boot lamp
Cigar-lighter
Clock
Hazard warning lamps
E Voltage regulator
Iqnition Reversing lamps
switch
Rear window heating element
Handbrake warning lamp
Window winder relay 16 Amps White R.H. Switch 0 R.H. window winder
L.H. Switch- L.H. window winder
Lighting
Switch 10 Amps Yellow Ashtray lighting
Cigar lighting
Heater controls lighting
Instrument panel lighting Clock
E Battery meter
Odometers
Sidelamp warning
L.H. sidelamps, front and rear 1 amp
Lighting
Switch 10 Amps Blue R.H. sidelamps, front and rear
Number-plate lamp CIRCUIT DIAGRAM
>
P.T.O.