Sunbeam RAPIER III SERIES Workshop Manual
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Sunbeam RAPIER III SERIES Workshop Manual

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  • Page 2 5th re-isue MANUAL WORKSHOP RAPIER Series Ill to IV Series I to IV Issued by ROOTES SERVICE DIVISION · COVENTRY ENGLAND World Exporters < ROOTES LIMITED • PICCADILLY • LON ::>oN ENGLAND Copyright reserved Ref.: W.S.M. 124/8 Part No. 6601102 Issued /964 PRINTED IN ENGLAND...
  • Page 3 re-issue NOTE reserve the Manufacturers, right ta alter time notice. specifications at any without...
  • Page 4 WSM, 124 st re-Issue Index Pace 3 FOREWORD ••• General Data Cooling System Engine Fuel System Clutch & Propeller Shaft Gearbox & Overdrive INDEX TO Front Suspension SECTIONS Rear Axle Rear Suspension Steering Brakes Wheels and Tyres Electrical System o dy Lubrication Oil Seals and Bearings Heating &...

  • Page 5: Genuine Parts

    I st re-issue WSM.124 Page 4 GENUINE PARTS Whenever replacement parts are required, ft is essential that only genuine replacement parts should be fitted. Genuine replacement parts are manufactured to the same specification and are of the same quality as those orig/ nally fitted to the car-and they are guaranteed.

  • Page 6: Foreword

    Page 5 FOREWORD Every possible care is taken during the manufacture of Sunbeam cars to ensure that they leave the factory capable of giving many miles of trouble-free motoring. Proper lubrication and maintenance are absolutely essential if satisfactory performance is to be maintained.
  • Page 7 re-issue WSM. 124 Page 6 Regional Offices ROOTES CONCESSIONAIRE C OMPANIES & REGIONAL OFFICES Tel. AUSTRALIA Tel. EUROPE Rootes (Australia) Ltd., Rootes (Belgique) S.A., 126, Rue de Linthout, 33.94.58 P.O. Box 100, and 33. 'J6.CS Port Melbourne, S.C.7, VICTORIA Australia. MJY.441 BRUSSELS, 4 Belgium.

  • Page 8: Table Of Contents

    WSM. 124 re-issue General Data Pace 7 GENERAL DATA CONTENTS Page No. BRAKES CAPACITIES ... COOLING SYSTEM DIFFERENCES-Alpine IV, Rapier IV (from B.94100001, B.33100001) ... DIMENSIONS ENGINE -Camshaft -Connecting rod -Crankshaft -Cylinder block -Cylinder head -General -Gudgeon pin -Performan�e -Piston ... -Table of road speed/engine speed -Valves ...
  • Page 9 WSM.124 re-Issue General Page 8 Data CONTENTS-continued Page No. ELECTRICAL SYSTEM-continued -Generator -Lamp bulbs -Lighting -Other equipment -Starter FUEL SYSTEM -Fuel pump -Carburettor IGNITION SYSTEM LUBRICATION SYSTEM STEERING SUSPENSION -Front -Rear -Shock absorbers TORQUE LOADING FIGURES TRANSMISSION -Clutch -Gearbox -Overall ratios shaft -Propeller -Rear axle...

  • Page 10: General Data

    WSM.114 re-issue General Data Page 9 GENERAL DATA GENERAL DIMENSJONS Wheelbase-Alpine 7 ft. 2 in. (218·4 cm.) -Rapier (243·8 cm.) 8 ft. Track (front)-Alplne (disc wheels) .. . 4 ft. 3 In. (129·5 cm.) -Alpine (wire wheels) .. . 4 ft. 3¼ In. (130·2 cm.) -Alpine IV (disc wheels) 4ft .

  • Page 11: General

    7th re-Issue WSM.124 Page 10 General Data ENGINE-GENERAL No. of cylinders Bore size (nominal) 3·11 In. (19 mm.) Ser. I Alpine, Series Ill Rapier 3·21 In. (81 ·5 mm.) Ser. II, Ill, IV Alpine, Series IIIA, IV Rapier. "A" grade standard, but subject to grading...

  • Page 12: Cylinder Block

    WSM.124 7th re-issue General Data Page 11 Alpine Ill (all models) 21.9mph 17.6mph 17.8mph 5.9mph 4.7mph 14.3mph 9.3mph 3.89: I axle ratio (35.2k ph) (28.3k ph) (23.0k ph) (14.9k ph) (9.5kp h) (7.5kp h) (28.6kph) Rapier (std) 4.55 : I 16.0mph 11.5mph 7.5mph...

  • Page 13: Crankshaft

    WSM.114 re-issue Page 12 General Data Length of valves (inlet and exhaust) 4·66 In. (118·36 mm.) Type of springs Dual Spring retention Cup and split cotters Valve spring-free length-Inner ... 1 ·93 In. (4·9 cms.) · 2·23 In. (5·66 cms.) -Outer Valve spring-fitted length-Inner I ·43 In.

  • Page 14: Connecting Rod

    re-issue WSM.124 General Data Page 13 Lubrication Pressure End thrust Thrust washer on centre bearing /·004 End float ... ·002 In. (·05/· I0 mm.) Main bearing running clearance ·0010 in./·0025 in. (on dla.) (·025/·063 mm.) Max. undersize for re-grinding ·06 in. (I ·52 mm.) (11 ·...

  • Page 15: Lubrication System

    WSM.12-4 re-issue General Data Page 14 No. of rings-Compression -Scraper Compression-Height 1 ·850 In. /1 ·845 In. (48·99/46·86 mm.) -Identification (mark on crown) ! M84 High or HC °I or LC R S 4 Piston length 3·25 In. (85·57 mm.) Max.

  • Page 16: Carburettor

    re-Issue WSM. 124 General Data Page 15 CARBURETTOR-Alpine 1-111 (early) Series II Series Ill (Std.) Series Ill (GT) Series I Series II element element With gauze type With dry *With gauze type With gauze type With dry cleaner type air type air cleaner air filter air filter...

  • Page 17: Cooling System

    re-issue WSM.124 Page 16 General Data CARBURETTOR-Rapier 111-IIIA Make 2 X Zenith Type 36-W.I.A. 2 or 36 WIA-3 36 WIA-3 Settings (Sea level to 4000 ft. [1219 m.]) IIIA Series Series Venturi 28 mm. 29 mm Main discharge jet 016289 016289 Main jet NOTE: when a 70 pump...

  • Page 18: Ignition System

    WSM.124 re-issue 12th General Data Page 17 k g. / cm. 2 ) Relief valve operating pressure-Alpine 1,11 7 lbs. in. · 49 9 lbs. ln. (·63 kg. / cm. -Alpine 111,IV ( · 28 kg ./ cm. 2 ) -Rapier 111,IIIA ...

  • Page 19: Clutch

    re-issue WSM.124 12th General Data Page 18 Champion N. 5* Spark plugs-Make and type (All models except Alpine Ill, Rapier IV) -Make and type (Alpine Ill, Rapier IV onwards) KLG.FE7St -Size .. . 14mm. -Gap .. . · 025 In. ( ·63 mm.) LA.45 0 53E Co!I maker's No.

  • Page 20: General Data

    WSM. 124 re-issue General Data Page 19 1·00: I l�:I Gearbox ratios-Top A// models -Third 1 ·39 : I 1·23:1 except -Second 2· 14 : I 1 ·89: I A/pine Alpine Ill -First 2·96:1 3.35 : I -Reverse 4·24 : I 3·75:1 Layshaft end float •006 in.

  • Page 21: Propeller Shaft

    re-issue WSM.124 Pa1e 20 General Data PROPELLER SHAFT (for torque loading figures see table at end of section) Type Open shaft (reverse spline) Outside diameter-Alpine 2·0 In. (5· 1 cm.) -Rapier 2·75 In. (6·9 cm.) Overall length-Alpine (Std.) (99·9cm.) 39·34 in. -Rapier (Std.) 51·841n.

  • Page 22: Dimensions

    WSM.124 re-issu e General Data Page 21 O/d Top O/d 3rd Third Second First Reverse OVERALL RATIOS Alpine 1,11 (std) 3.89:1 5.41:1 8.33:1 13.01: I 16.48;1 Alpine 1,11 (O/d) ... 3.39:1 4.22:1 4.72:1 5.88:1 9.04:1 14.13:1 17.90:1 Alpine 111 (all models) 3.12:1 3.89:1 3.85:1...

  • Page 24: Brakes

    WSM.124 re-issue General Data Page 23 SUSPENSION CONTROL Shock Absorber-Make (Alpine) Armstrong -Make (Rapier) Girling -Type Hydraulic -Linkage Rubber bushed Sway eliminator-Type Torsion bar between front suspension links STEERING (for torque loading figures see table at end of section) Make and type Burman "F"...

  • Page 25: Wheels And Tyres

    WSM.124 re-issue Page 24 General Data WHEELS AND TYRES (Alpine) Road wheels-type Pressed steel disc or wire 4Jx 13 -Size No. of wheel studs Max. permissible "run-out" at wheel rim ·07 in. (1 ·8 mm.) Max. permissible "lift" at wheel rim ·07 In.

  • Page 26: Battery

    re-issue WSM. 124 General Data Page -Pressures• Normal motoring - 5.60 x 15 tyres Front: 24 lbs. in. (1·69 kg. cm. Rear: 24 lbs. in. (1 ·69 kg. cm Fully laden - 5.60 X 15 ., Front: 24 lbs. in. (1·69 kg.

  • Page 27: Lamp Bulbs

    7th re-issue WSM.12-4 Page 26 General Data LIGHTING System Earth return Headlamp type P.700 Sldelamp type-Alpine L.594 -Rapier L.539 -Rapier L.662 LAMP BULBS Head- Home and Export R.H.D. Lucas No. 414 12V. 50/40W. (Sealed beam on Al pine 11 1 Rapier IV onwards) Export L.H.D.
  • Page 28 WSM.124 5th re-issue General Data Pase �7 Alpine IV and Rapier IV (Differences from B.94100001 and B.3100001) CAPACITIES 3i pints (4·2 U.S. pints; 1 ·9 litres) Gearbox oil-Std -4½ -0/0 pints (5·4 U.S. pints; 2·5 litres) CARBURETTOR SETTINGS (Rapier only) P rimary throttle main jet GEARBOX Gearbox ratios-Top...

  • Page 29: Torque Loading Figures

    WSM.124 re-issue General Data Pa1e28 TORQUE LOADING FIGURES ENGINE Cylinder head (tighten when cold) ... 48 lbs. ft. (6·6 kg.m) Crankshaft (mains) 55 lbs. ft. (7·6 kg.m) Con. rod (blg-end)-Serles I Alpine, Series Ill Rapier 20 lbs. ft. (2·7 kg.m) 24 lbs.
  • Page 30 WSM.124 General Data Page 29 BRAKES (Front) Brake disc to hub 38 lbs. ft. (5·2 kg.m) Caliper to adaptor 52 lbs. ft. (7· 1 kg.m) · · ·{ 38 lbs. ft. (5·2 kg.m) Steering arm to carrier and adaptor 60 lbs. ft. (8·2 kg.m) Adaptor to carrier 38 lbs.
  • Page 31 WSM.12'4 re-Issue Section A ( Cooling System ) Pa1e 1 COOLING SYSTEM CONTENTS Page No. GENERAL DESCRIPTION ... RADIATOR RELIEF VALVE DRAINING AND REFILLING THE COOLING SYSTEM FROST PRECAUTIONS -Without using anti-freez.e -Using anti-freez.e -Heaters ... COOLING SYSTEM -To clean ... THERMOSTAT -To remove and refit -To test...
  • Page 32 2nd re-Issue WSM.124 Pa1e 2 Section A (Cooling System) COOLING SYSTEM All threads are of the Unified series and the appropriate spanners must be used To accomplish this, a thermostatically operated GENERAL DESCRIPTION ·.J valve Is located In a cast-iron body bolted to the Water Is circulated by an ·...
  • Page 33 WSM.124 2nd re-issue Section A (Cooling System) Page 3 attempting to drive the vehicle. If this Is neglected there is a danger that the radiator may freeze if the car is driven in temperatures below freezing point before the thermostat is open. In cold weather the bottom of the radiator should be blanked off so that its bottom tank keeps warm, because it is here that freezing commences.
  • Page 34 re-Issue WSM.12-4 Page 4 Section A (Cooling System) Heaters Finally, flush the system thoroughly with running water by means of a hose, turn off drain taps and Where a heater unit is installed, a reliable anti­ fill system to normal level with soft water or anti­ freeze mixture must always be used, because even freeze mixture as required.
  • Page 35 WSM.124 3rd re-issue Section A (Cooling System) Pages To test most important that the interconnecting cable between ·the the gauge and temperature element Suspend unit in a vessel of water with a reliable should not shorted to earth when the Ignition is thermometer.
  • Page 36 WSM.12-4 re-Issue Section A (Cooling Page6 System) COVER PLATE IMPELLOR FAN PULLEY CENTRE .040"' (1.01 mm.) BEARING BODY THROWER UNIT Sectionol view of water pump Fig. l. ALPINE SERIES I AND RAPIER 111 '4·00"-'4-0I• (101•6-101·8 mm.) ALPINE SERIES II AND 111-4-865'-4•875• (121·5-123·8 mm.) back cover plate.
  • Page 37 WSM.124 / st re-Issue Section A (Cooling System) Page 7 Replace the bearing locating screw in the top of the pump body. Place the fan pulley centre on a press table and press the larger diameter of the spindle Into the pulley centre, as Illustrated in Fig.
  • Page 38 WSM.124 I st re-issue Section A (Cooling System) Pase 8 S. Support the pump spindle end inside the fan cover plate. This clearance can be checked with pulley centre as shown in Fig. 4 and press the feelers and straight edge as shewn In Fig. 5. lmpellor on to the shaft until the lmpellor is in the position shown In Fig.

  • Page 40: Starter

    WSM.124 2nd re-issue Section B (Engine) Pagel CONTENTS CYLINDER BLOCK AND PISTONS-continued Pa1e No. -Piston and connecting rod assemblies-To remove -To remove gudgeon pin -To assemble ... -Gudgeon pin fits -To refit -Piston rings-Details and fitting -Piston and Cylinder Bore Grading Letters-Explanation -Fitting pistons to cylinders (Low mileare engines) CYLINDER HEAD AND MANIFOLDS...
  • Page 41 st re-issue WSM.124 Section B (Engine) Pagel CONTENTS LUBRICATION SYSTEM-continued Page No. -Oil pressure relief valve -Oil pump-Description -To remove -To dismantle and check clearances -To refit -To clean intake filter -Oil sump-To remove and refit VALVES AND VALVE GEAR -Examination of valves, springs, guides, etc.
  • Page 42 WSM, 114 1st ,�issue Section B (Engine) Page4 Fig. En1lne--lon11tudinal section (l494c.c. enrlne shown)
  • Page 43 WSM.12,t 3rd re-issue Section B (Engine) Pa ge s OIL FEED TO VALVE ROCKER GEAR OIL FEED FROM PUMP Engine-Cross (1494 shown) Fl1, 2. section c.c. engine...
  • Page 44 WSM, 124 3rd re-Issue Page 6 Section B (Engine) Fl1, 3 Cylinder block and associated parts (/494 c.c. enrine shown)
  • Page 45 WSM.124 6th re-Issue Section B (Engine) Pa g e7 7397 view working parts (/494 c.c. engine shown) Fis, 4. Exploded ·...
  • Page 46 WSM, 124 re-issue Section B (Engine) Page8 ENGINE A non return ball valve was titted In the timing ENGINE (See Figs. I to 4) chain oil feed pipe union, to ensure rapid building Details and differences up of oil pressure when starting. Full particulars are given In the Data Section of the B.30Sn7o HC, B.3057825 LC, B.9110982 From chassis...
  • Page 47 re-issue WSM, 124 Section B (Engine) Page9 GENERATOR low speed driving. Cleaning and regapplng of To adjust belt tension the sparking plugs is all that is required (see The generator .is driven from the crankshaft by a Fig. 6). White to yellowish powdery deposits belt which also drives the water pump and fan.
  • Page 48 WSM. 124 Page 10 Section B (Engine) Sparking Plugs-To clean and adjust Plugs should be cleaned with an air blast cleaner and before setting the plug gaps the electrode tips should be filed lightly to remove all traces of burning. The gap setting of sparking plugs is very Important and points should be correctly set by bending the earthing (side) electrode.
  • Page 49 re-Issue WSM.11.C Section B (Engine) Page II .,,,,,,,,,, IGNITION VERNIER ADJUSTMENT Fig. 11. vernier Distributor control TO TIME IGNITION Two adjustments are provided for setting the ignition tlmlng- Static Ignition settings are given In the Data Section (a) A clamp screw mounted horizontally below under "Ignition System".
  • Page 50 WSM.114 3rd re-issue Page 12 Section B (Engine) Fig. No. I and 4 cylinder T.D. C. pointers-Insert shows T.D.C. to 30 8. T.D.C. timing marks added from Rapier Series IV I 3. ° and later Alpine Series Ill. To Check Timing-Method I and a good earth.
  • Page 51 st re-issue WSM.124 Section B (Engine) Page 13 STROBOSCOPIC TIMING LIGHT-Uses for this engine speed on Alpine and Rapier engines is 3 crankshaft degrees BTDC. The stroboscopic timing light provides a rapid and convenient means of setting the ignition timing Example-in crankshaft degrees and checking the action of the centrifugal and °...
  • Page 52 WSM.124 st re-issue Section B (Engine) Page 14 ° ° This is 16 crankshaft centrifugal advance plus 8 made with the vernier control on the distributor static advance timing. until the lowest stop watch reading is obtained. Several test runs have to be made ON THE °...
  • Page 53 WSM. 124 Section B (Engine) Page 15 The distributor rotor is now adjacent to No. I H.T. turning the engine progressively through two connection in the distributor cap. No. I H.T. lead revolutions to complete the cycle of adjustment. should be fitted to this connection and No. I To check clearance, Insert a feeler gauge of correct cylinder spark plug and the other H.T.
  • Page 54 • WSM.114 Section B (Engine) Page 16 4786 INLET INLET INLET INLET EXHAUST EXHAUST EXHAUST EXHAUST Fig. IS. Plan view of valve rocker gear No. I exhaust is adjusted when No. 4 exhaust No. 4 exhaust is adjusted when No. I exhaust is fully open.
  • Page 55 I st re-Issue WSM.124 Section B (Engine) Page 17 TIMING COVER Remove the setscrew, tab washer, and plain washer from front end of camshaft. To remove Remove oil thrower in front of crankshaft sprocket. Drain and remove radiator. Pull or lever off both camshaft and crankshaft Slacken the generator mounting screws and remove wheels simultaneously.
  • Page 56 WSM.124 rE-issue Section B (Engine) Page 18 timing is correct it should be approximately 17 mm. before the timing cover T.D.C. pointer. If the valve timing is one tooth out, the mark EXHAUST on the crankshaft pulley will be a considerably CLOSES greater distance before T.D.C.
  • Page 57 WSM.124 I st re-issue Page 19 Section B (Engine) CAMSHAFT BEARINGS Loosen exhaust pipes from engine at the •y' (Alpine only). junction in the exhaust pipe To remove Disconnect exhaust pipe at exhaust manifold flange Using special tool (V. L. Churchill RG 32), the front (Rapier only).
  • Page 58 WSM.124 Page 20 Section B (Engine) Remove eight bolts and two nuts and washers To remove securing cylinder head to cylinder block and lift off Drain cooling system. cylinder head. Remove air cleaner where fitted. Cylinder head gasket Disconnect header tank to radiator hose, and over­ All gaskets are stamped with the word "TOP"...
  • Page 59 WSM.124 re-issue Section B (Engine) Page pointed instrument or emery cloth may be used Do not on any account use abrasives for removing carbon, or damage will result. Having attended to the preceding operations and given the valves and seatings any attention that may be required, the engine may be reassembled.
  • Page 60 WSM.124 2nd re-issue Section B (Engine) Page 22 Springs. If possible the load required to compress the valve springs to their fitted heights should be checked. The required load and length to compress the springs Is given In the Data Section under "Valves".

  • Page 61: Valve Guides

    WSM. 114 re-issue Section B (Engine) Page 23 After thoroughly cleaning off all traces of grinding paste from the valve and seating with a dry cloth, test by placing a small amount of engineers' marking on the seating and revolving the valve In place not "' more than about i (3 mm.) In each direction.
  • Page 62 I st re-issue WSM. 124 Page 24 Section B (Engine) cylinder head is heated to the proper temperature. VALVES THEY CANNOT BE DRIVEN OUT OF A COLD To reface CYLINDER HEAD. If, on examination of the valves it appears unlikely that they would clean up satisfactorily with ordinary New valve guides must have a proper interference grinding In, they must be refaced.
  • Page 63 WSM.124 re-issue Page 25 Section B (Engine) generally it will be found that these are better than the valves as regards condition unless the engine has been a very long time in service. It is quite practicable to reface the valves and grind them in on the seatings if the latter are in good order.
  • Page 64 WSM.12-4 2nd re-issue Page 26 Section B (Engine) cutting tool and a valve seat grinder. The later Is preferable for facing valve seat Inserts. EXHAUST AND INLET VALVE SEAT INSERTS (See Fig. 30) These inserts can only be fitted when the cylinder °...
  • Page 65 WSM.124 / st re-Issue Section B '(En1ine) Page27 5. Flt the insert ensuring that It beds on the The timing gears are lubricated by a jet of oil from bottom face of its recess. a small hole drilled in the side wall of a small diameter pipe which is supplied with oil from the front main bearing oil feed.
  • Page 66 WSM.124 1st re-issue Section B ( Engine) Page 28 : � , - • \ __ \ ______ .,,! ' i ' ' ! '. , { l ! l � \ \ ' J , , . - - - - 4-904- �-------- ---\ ,�-...
  • Page 67 re-issue WSM.124 Page 29 Section B (Engine) centre camshaft bearing oil feed hole, and the oil hole feeding to the valve rocker oil feed pipe. See Fig. 31 and its inset ( I 0). By this means a controlled quantity of oil Is fed at a much reduced pressure through an internal pipe to the valve rocker shaft.
  • Page 68 WSM.12,4 3rd re-issue Page Section B (Engine) element, up from the inside of the element and down through the steel tube fixed in the filter base to compartment .. A" which feeds to the main oil gallery. See Fig. H. The steel tube inside the filter prevents the oil draining out of the filter when the engine Is not running.
  • Page 69 WSM.124 I st re-issue Section B (Engine) Page 31 Fig. White arrows show direction of oil flow Oil pump-cut away view. will be appreciably reduced in compartment "A" Run engine and carefully check for o/1 leaks. due to starvation, and this will allow the by-pass Examine sump level after running engine as cne valve to open, in turn ensuring a feed to the oil pint of the oil will be taken to fill the filter.
  • Page 70 WSM.124 Page 32 Section B (Engine) Oil pump intake filter-to clean DIRECTION OF ROTATION Whenever the sump is removed the opportunity should be taken to clean this filter. Remove spring clip from oil pump shroud and withdraw gauze. The gauze should be washed in petrol or paraffin and blown dry with clean com­...

  • Page 72: Piston And Connecting Rod

    WSM.124 Page 34 Section B (Engine) CRANKCASE DILUTION To remove pistons and connecting rods Dilution of the lubricating oil may be brought about Remove cylinder head. by the addition of poor quality oil, or by fuel leaking Remove sump. past pistons and rings. The latter condition may be due to worn bores, pistons and rings, and Is most Remove the self-locking nuts securing big end likely to occur In cold weather.
  • Page 73 WSM.124 re-issue Section B (Engine) Page 35 Tighten nuts to the correct torque given in the recommended for honing new little end bushes to Data Section under "Connecting Rod". standard size or to + 003" ( ·076 mm.) oversize. It can also be used to hone out the piston bosses to IMPORTANT take the oversize gudgeon pin.
  • Page 74 re-issue WSM.124 Page 36 Section B (Engine) Fig. 39. Delapena precision honing machine -ooos· only (·012 mm.) of material has to be removed Connecting Rod Alignment in order to allow the gudgeon pin to enter. After fitting and honing, or reaming a new connect­ ing rod little end bush to size, the connecting rod Honing of Piston Bosses (See Fig.

  • Page 75: Piston Rings

    WSM.124 re-issue Section B (Engine) Page 37 Fig. 42. Checking connecting rod alignment PISTON RINGS Top Compression Ring This piston ring is chromium plated with the word "Vacrom" etched on one of its side faces. It may Fig. 40. Honing connecting rod little end bush be titted either way up and is Cargraph treated to assist bedding In.
  • Page 76 WSM.124 2nd re-issue Page 38 Section B (Engine) that It should be fitted uppermost. Incorrect fitting will result In higher oil consumption. Scraper ring One slotted type scraper ring Is fitted In the third groove. No piston ring is fitted to the fourth (lower) groove which Is only provided on 1494 c.c.
  • Page 77 re-issue WSM.114 Section B (Engine) Pa1e 39 2. From the size obtained subtract the correct highest and lowest cylinder bore limits, in which piston clearance previously given and from this there are four grades is ·0016" (·040 mm.). size choose a suitable grade of piston. means of the grading system the correct piston tit is obtained when pistons are titted to new cylinder Example...
  • Page 78 re-issue WSM.124 Page40 Section B (Engine} complete with pistons are not serviced under one part number. It Is essential to ensure that each new piston is fitted into a bore of appropriate grade. CYLINDER LINERS To flt SPRING These Instructions apply to engines which are not BALANCE fitted with liners during initial assembly.
  • Page 79 WSM.124 re-issue Section B (Engine) Page 41 thus allowing the liner to correct any misalignment, may be drawn or pressed out from the bottom only. Check the cylinder for concentricity and correct size for the full length. If the diameter is in excess of the dimension given on the previous page, the correct interference fit will not be obtained.
  • Page 80 WSM.124 Page41 Section B (Engine) Fig. 48. E.N 16 identification marks crankshaft Top half bearings are replaced in a reverse manner steel washers having white metal thrust faces. These faces are easily recognised by the two to that described for removal. The following points should be noted:- vertical oil grooves cut across the white metal.
  • Page 81 WSM.124 Section B (Engine) Page 43 Crankshafts-Regrinding The correct, and maximum permissible undersizes are given in the Data Section under "Crankshaft". These must be used when regrinding crankshafts. Not more than ·005" (·127 mm.) can be removed from each thrust face at the ends of the crankshaft centre journal.
  • Page 82 WSM.124 Section B (Engine) Page 44 reconditioning by the manufacturers. To eliminate the possibility of fire, keep However, container covered by a metal lid to prevent suitable equipment Is available, the starter ring may be removed and replaced by adopting the following flame from reaching the surface of the oil.
  • Page 83 WSM.124 Section B (Engine) Page 4S Oil pressure relief valve. (See Fig. 53) A piston type relief valve, situated in compartment "C" in the filter adaptor casting, opens to return all excess oil delivered by the oil pump to compart­ ment "B"...
  • Page 84 WSM. 114 Section B (Engine) Page 46 Changing throw away filter unit. (See Fig. 52) Screw the filter (7) into position until it just touches the joint face on the adaptor casting. THEN To remove- SCREW THE FILTER A FURTHER ONE THIRD The rubber joint ring (2) on the filter base tends to OF A TURN BY HAND ONLY.
  • Page 85 RO OTES MAN UAL WSM. 12-4 Section B (Engine) Page 47 Fig. 55. system. Closed crankcase ventilation The flame trap was not fitted to the first arrange­ CLOSED CRANKCASE VENTILATION ment of this system which had a direct hose connection SYSTEM from the oil filter tube on the rocker cover to the This crankcase ventilation system i�...
  • Page 86 RO OTES HAN UAL WSH. 12 .. Page 48 Section B (Engine) the pipe (I) and for ventilation air to be drawn I. Check that the engine idles correctly. When from the "clean" side of the air cleaner, into the idling It should be possible to push the valve (7) crankcase rocker cover through the pipe (4), hard against Its seat;...
  • Page 87 WSM. 124 re-Issue Section C (Fuel System) Pace 1 FUEL SYSTEM CONTENTS Page No. FUEL PUMP -Details of operation -Glass bowl filter -Hand primer -Fuel shortage at carburettor -Testing fuel pump when fitted to engine -To remove fuel pump from engine -To dismantle fuel pump -Inspection of parts -To reassemble fuel pump...
  • Page 88 WSM.124 re-issue Section C (Fuel System) Page 2 CONTENTS-continued Page No. -Diagnosis of faults -Excessive fuel consumption -Insufficient top speed -Bad slow running -Poor performance at small throttle opening -Poor acceleration ... -Difficult starting from cold ..:..Difficult starting when hot -Adjustments -Synchronisation of throttles and slow running adjustment -Throttle, fast idle for starting ...

  • Page 89: Fuel Pump

    WSM.12.C Section C (Fuel System) Page 3 FUEL PUMP The A.C. mechanically operated pump is mounted (12) thus creating a depression In the pump chamber on the right-hand side of the engine and operated (15). Fuel drawn from the tank enters the glass (3).

  • Page 90: Glass Bowl Filter

    WSM.124 Section C (Fuel System) Page 4 tighten the securing screw or the excessive pressure carburettor bowl is full the float will shut the needle valve, thus preventing any flow of fuel from the will cause rapid deterioration of the joint. pump chamber (15).

  • Page 91: To Remove Fuel Pump From Engine

    'W'S'M. Section C Page 5 (Fuel System) over by hand tools after correctly locating the TO REMOVE FUEL PUMP FROM ENGINE various components. Disconnect the fuel pipes by undoing their unions on the fuel pump body. Remove the two nuts All badly worn parts must be renewed and very holding the pump to the engine crankcase and lift little wear may be tolerated on the rocker arm pin,...

  • Page 92: To Test Fuel Pump After Assembly

    WSM.124 Section C (Fuel System) Page 6 should be at the position shown in fig. 3. After When first fitting diaphragm Engine Mounting assembly pump body, turning the diaphragm assembly a quarter turn to Flange locating "tab" on diaphragm the left the "tab" should be In the position indicated should be In this position.

  • Page 93: To Refit Pump To Engine

    st re-issue WSM.124 Section C (Fuel System) Page 7 the suction pipe clear of the paraffin (kerosene.) EXCESSIVE FUEL PUMP PRESSURE Again operate pump. Not more than 16 strokes As explained under, "Details of Operation" should be necessary to secure delivery of paraffin the pressure of fuel on the carburettor is determined from the pump outlet.
  • Page 94 WSM.12 .. Page 8 Section C (Fuel System) Body. Retainer-glass cover. 3 · Glass bowl. Gasket-bowl. Cover. FIiter gauze. Valve. Gasket-valve. Retaining plate-valve. Screw-valve retainer. Screw No. 10 U.N.F. Washer ¼ spring. Pull rod and diaphragm. Spring-diaphragm. Priming lever. Washer-oil seal. Retainer-oil seal.

  • Page 95: General Description

    st re-issue WSM.124 Section C (Fuel System) Page 9 CARBURETTOR A heat insulating joint of 5 mm. thickness is used GENERAL DESCRIPTION between the throttle spindle body and the main The following carburettors and air cleaners are body, to reduce heat flow from the manifold to fitted as standard equipment float chamber and jets.
  • Page 96 Page 10 SUNBEAM Section C (Fuel System) SLOW RUNNING AIR INTAKE EKTERNAL AIR INLET TO. FLOAT CHAMBER AIR SUl'PL Y CHANNEL TO ACCELERATOR PUMP NOZZLE SLOW RUNNING CHANNEL FUEL FEED CHANNEL FROM SLOW RUNNING THROTTLE STOP SCREW CHANNEL FEEDING FROM...
  • Page 97 SUNBEAM Page 11 Section C (Fuel System) EXTERNAL AIR. INLET TO FLOAT CHAMBER. SUCTION PASSAGE TO BY-PASS VALVE OPERATING DIAPHRAGM AIR. SUP. P LY CHANNEL TO ACCELERATOR. PUMP NOZZLE SLOW-RUNNING CHANNEL FUEL FEED CHANNEL FR.OM SLOW RUNNING JET THROTTLE STOP...

  • Page 98: Starting From Cold

    S U[N BEAM Page 12 Section C (Fuel System) valve. The latter is only used on WIA carburettors. mechanism opening the throttle to the correct starting position, when the choke control is pulled The float chamber is vented to atmosphere by a out to start the engine.

  • Page 99: Slow Running

    WSM.124 Section C (Fuel System) Page 13 can open against a light spring, even when the Slow running (See Fig. 9) choke control is still pulled out. With the throttle in the idling position, the mixture When the engine starts, with the choke valve is supplied by the idle jet which draws fuel through closed, air pressure acts on the larger pivoted area the crossholes at the lower end of the main dis­...
  • Page 100 Page 14 SUNBEAM Section C (Fuel System) wider and increase the engine speed and when To weaken the mixture, the screw should be turned unscrewed the speed will be reduced. clockwise; conversely it must be unscrewed to make the mixture richer.
  • Page 101 st re-issue WSM.124 Section C (Fuel System) Page 15 with. Fig. 9 illustrates carburettor action under mixture is given over the light throttle to full idling conditions, and the inset, the progression throttle range. holes which operate on fast idling. On the WIA carburettor part throttle operation is similar to the WIP carburettor, but at wider Part and full throttle operation (See Fig.

  • Page 102: The By-Pass Jet

    I st re-issue WSM.124 Section C (Fuel System) Page 16 to cause a fuel discharge. This fuel supplements tight compartment that Is connected by a passage­ that already metered by the main Jet, and by-pass way to the engine side of the throttle valve (see Jet on WIA carburettors.
  • Page 103 Page 17 Section C (Fuel System) SUNBEAM At about three-quarters throttle opening the engine The accelerator pump (See Figs. 12 and 13) suction In the inlet manifold becomes insufficient To ensure immediate acceleration when the throttle to hold the diaphragm and its plunger up against Is suddenly opened, a controlled and metered supply its return spring pressure.
  • Page 104 Page 18 S,UNBEAM Section C (Fuel System) the pressure exerted by the fuel pump through a the cylinder is charged with petrol admitted from small calibrated hole into a space In the nozzle . the floatchamber through the non-return valve. The piston is spring-loaded, and Is retained in its This space is in communication with the float cylinder by a shouldered screw.

  • Page 106: Diagnosis Of Faults

    WSM.12-4 Page 20 Section C (Fuel System) 2. Examine induction manifold and carburettor Provision is made for varying the pump travel, and long or short strokes may be arranged. These flange for air leaks. positions are shown and explained in Fig. 14. 3.

  • Page 107: Insufficient Top Speed

    WSM.124 Section C (Fuel System) Page 21 Insufficient top speed Check that main met . e ring jet is as specified and that It is properly tightened. See that throttle valve is opening fully over the range provided by the particular carburettor ( d ) On WIA carburettors check that by-pass valve stop plate arrangement.

  • Page 108: Poor Performance At Small Throttle Opening

    WMS.124 Page 22 Section C ( Fuel System ) little jointing compound should be used pump cylinder is clean and will close effectively, and that the assembly is screwed tightly Into between Insulator faces and body faces. the base of the float chamber. (f ) Remove the slow running volume control screw and see that Its tapered end is In good (d) Two settings are available for the pump stroke...

  • Page 109: Difficult Starting When Hot

    /st re-issue WSM. 124 Section C (Fuel System) Page 23 sticking in the closed position, due to formation of strangler. Any fuel that runs into the Inlet manifold gummy deposit from petrol or additives. should drain away through the inlet manifold drain pipe and a check should be made to see that this pipe and its ball valve end are clear.
  • Page 110 st re-issue WSM. 12.C Page 24 Section C (Fuel System) . ._/ 1. Volume control screw. fiitted item 4 is used) (not 2. Slow running speed adjustment screw. 3. Coupling yoke clamp bolt .. 4. Slow running air adjustment screw. fitted item I is used) (not...

  • Page 111: Throttle, Fast Idle For Starting

    re-Issue WSH. 124 Section C (Fuel System) Page 2S 4. Screw in front carburettor throttle stop screw 9. After the slow running is correct a check must be made to ensure that under full throttle con­ (2) until it just touches its abutment as the throttles are held closed;...

  • Page 112: Accelerator Pump Stroke

    re-issue WSM.124 Page 26 Section C (Fuel System} when the carburettors are supplied with a head of fuel giving a similar pressure to that of the correct fuel pump output pressure. The fuel levels must be similar and can be checked with both carburettors in position in the following manner:- 1.

  • Page 113: Choke Control

    WSM.114 Section C (Fuel System) Page 27 Choke control-To adjust (See Fig. 15) 4. Remove four cheese-headed screws holding throttle body to carburettor body, and lift out 1. Slacken the two set screws holding the choke venturi after removing its locating screw. operating cable and the choke Interconnecting rod to the spindle (1) shown in Fig.
  • Page 114 WSM.124 Page 28 Section C (Fuel System) SMALL LARGE VENTURI VENTURI HAIN DISCHARGE ACCELERATOR PUMP DISCHARGE NOZZLE HIGH-SPEED AIR FEED PASSAGE BLEED TO DISCHARGE NOZZLE ACCELERATOR PUMP BY-PASS DISCHARGE NOZZLE OPERATING FIXING SCREW DIAPHRAGM (PUMP DISCHARGE VACUUM FEED BALL VALVE IS PASSAGE UNDER FIXING SCREW)

  • Page 115: Inspection And Cleaning

    st re-issue WSM.114 Section C (Fuel System) Page 29 The carburettor is now dismantled sufficiently for around the metering jet just above Its hexagon cleaning. There is no need to remove the high head, must be In good condition. speed bleed and this cannot be done without 6.
  • Page 116 WSM.124 Page 30 Section C (Fuel System) " , ,,----, ,_,.; , __ -.-,; , --2$ ��IIC!!l',�27 5095 Exploded Fig. 18. view carburettor. Items 76 to 80, Inset, used on the shown ,n are only WIA carburettor...
  • Page 117 I st re-issue WSM.124 Section C (Fuel System) Page 31 CARBURETTOR PARTS-See Fig. 18 . 42 Slow running volume control screw. 1 Cover screw. 43 Washer¼" spring Throttle body ° 2 Spring washer. _t_• B S F . • • X 1•...
  • Page 118 WSM.12A Section C (Fuel System) Page 31 Swill the filter gauze (which is attached to the Replace the oil bath container, refit the filter cover) in paraffin (kerosene) and blow dry with cover with gauze and tighten thumb screw. an air line or allow to drain thoroughly. Tighten the clip on the hose connection on the Clean out the oil bath and refill with clean engine oil up to the level mark.
  • Page 119 WSM.124 7th re-/nue Sec. D (Clutch & Prop. Shaft). Pap 1 CLUTCH AND PROPELLER SHAFT SECTION D CONTENTS Pare No. CLUTCH UNIT -Adjustment of clutch ... -To remove and refit release bearing -To remove and refit driven plate ... -To dismantle and reassemble pressure plate assembly -Staking locknuts Diaphragm Clutch -To Remove and Refit Release Bearing...

  • Page 120: Clutch Unit

    WSM.114 7th re-Issue Pagel Sec. D (Clutch & Prop. Shaft) CLUTCH UNIT Description Serles Alpine Series I and Rapier Ill cars An 8 single dry plate A type clutch is fitted incor­ porating a copper impregnated graphite (MY3D) release bearing which is self-lubricating. attention in the way of lubrication to the release bearing Is necessary.

  • Page 121: Sec. D (Clutch & Prop. Shaft). Pap

    WSM.124 4th re-issue Sec. D. (Clutch & Prop. Shaft) Pagel by-pass port, due either to the hole being covered the cylinder and push rod. Unscrew the filler cap by the main cup as a result of incorrect pedal adjust­ and drain the fluid into a clean container. ment, or to the holes being choked by foreign Slightly compress the external return spring (56), matter, pressure will build up in the system.
  • Page 122 4th re-Issue WSM.124 Page4 Sec. D. (Clutch & Prop. Shaft) components (A/pine Series Series cars) Fl1, 3. Exploded view-Clutch and slave cylinder I, II and Ra � ler To assemble To refit Flt the secondary cup { 11) on the piston { I 0), so that Flt the boot (12) on the cylinder (5) so that the vent the lip of the cup faces the piston head, and gently hole In the boot will be at the bottom when the...
  • Page 123 re-issue WSM.124 Page 5 Sec. D. (Clutch & Prop. Shaft) 54-61 Fig. 4. Master cyllnder, sectional view Filler Cup 5, Cylinder Piston Wuher I 3, Stop Cirdip Wuher Return Sprine 10, Piston 14, Puah Rod (Alpine Series I 7. Sprine Retainer \k �-.:b=���...
  • Page 124 WSM.124 5th re-issue Sec. D. (Clutch & Prop. Shaft) Page6 at least a quarter full throughout the operation. If this is not done, air will be drawn In necessitat­ ing a fresh start. Attach a rubber tube to the bleeder screw (..0) -Fig.
  • Page 125 WSM. 124 re-issue Sec. D. (Clutch & Prop. Shaft) Pase Bleed hydraulic system at operating cylinder. Note.-On a new replacement clutch assembly It will be found that there are three small L-shaped "keepers" between the release levers and the clutch cover. These are painted red and are fitted to enable a clutch unit to be fitted to a flywheel without the necessity of compressing the springs In the cover Into position by means of the fixing bolts.
  • Page 126 WSM.124 re-issue Pages Sec. D. (Clutch & Prop. Shaft) To dismantle Using 99A Equipment With the base plate on a flat surface, wipe the work face and place the No. 2 Spacers In position over the letter given on the code card. Place the clutch on the spacers while aligning the mounting holes In the cover with the appropriate tapped hole_ s in the base, and check that the spacers are...
  • Page 127 WSM.124 re-issue Sec. D (Clutch & Prop. Shaft) Page9 Adjusting the Release Lever Height Using 99A Equipment With No. 2 Spacers In the correct position on the base plate and the assembly firmly bolted to the base plate. Screw In the actuator and operate the lever about a dozen times to settle the release mechanism.
  • Page 128 re-issue WSM.124 (Clutch Pa1e 10 Sec. D & Prop. Shaft) Using a new driven plate clamp the clutch assem­ bearing rear universal joint Incorporating a bonded bly to a flat surface having a hole large enough to rubber vibration damper as shown in C, Fig. 12, or take the protruding boss of the driven plate, until a metal to rubber rear universal joint as shown In the clutch cover makes firm even contact with the...
  • Page 129 -4th WSM. 124 re-issue Sec. D (Clutch & Prop. Shaft) Page 11 6385 ________ ..,. Fig. 12. Exploded view of propeller shaft. matter, no hand fitting or special tools being only parts subject to wear after prolonged service required. and when It becomes necessary to replace these for ·...
  • Page 130 4th ,�issue WSM.124 Page Sec. D (Clutch & Prop. Shaft ) universal joint, (Inset B, Fig. 16), the rear Joint can­ not be overhauled In service, and in the event of a new Joint must be fitted. Normally, no damage purpose wlll be served by removing the Joint from the propeller shaft, but if this becomes necessary, the universal joint and the propeller shaft should...

  • Page 131: Diaphragm Clutch

    WSH.124 Sec. D (Clutch & Prop. Shaft) Page 13 DIAPHRAGM CLUTCH(Later Models) cover strap drive bolts. Description The diaphragm spring is pinched between two fulcrum rings (3) which are secured to the cover A single dry plate type clutch is fitted, Incorpor­ by special rivets (8).
  • Page 132 WSM. 124 Page 14 Sec. D (Clutch & Prop. Shaft) Operation Under no circumstances must the clutch be lifted or pulled by means of the thrust plate or the straps When the cover assembly and driven plate Is bolted will be bent and the alignment of the thrust plate to the flywheel, the diaphragm spring comes under destroyed.

  • Page 133: Master Cylinder

    WSM.124 /st re-issue Section D (Clutch & Prop. Shaft) Page 15 7293 Fig. Sectional view of master cylinder I. FILLER CAP 6. SPRING 10. PISTON 14. RUBBER BOOT 2. WASHER 7. SPRING RETAINER SECONDARY CUP PUSH ROD ASSEMBLY MAIN CUP 3.

  • Page 134: Slave Cylinder

    WSM. 124 re-issue Section D (Clutch & Prop. Shaft) Page 16 pedal adjustment, or to the holes being choked by retainer (7) on the smaller end of the return spring foreign matter, pressure will build up in the system. and Insert the assembly into the cylinder. Insert In order that the rubber cup shall not be drawn Into the main cup (8) Into the cylinder, lip foremost, taking care not to damage or turn back the lip of...
  • Page 135 WSM.124 re-issue Section E (Gearbox & Overdrive) Page 1 GEARBOX AND OVERDRIVE SECTION E CONTENTS GEARBOX Page Page OVERDRIVE unit Gearbox Working principles -to remove and refit The hydraulic system Clutch housing -to remove ... Control of overdrive Top cover Lubrication and maintenance -to remove and refit -to dismantle and reassemble...

  • Page 136: Bleeding The System

    WSM.12,t re-issue Section E (Gearbox & Overdrive) Page 2 GEARBOX GENERAL DESCRIPTION Rapier A four-speed gearbox is fitted having synchromesh Place the car on a ramp or over a pit. on the upper three ratios. Of these, second and Disconnect positive lead from battery. third employ helical gears, and are in constant mesh.

  • Page 137: To Remove And Refit

    re-issue WSM.124 Page_l Section E (Gearbox & Overdrive) TOP COVER retaining cap to the extension casting and take off the cap, spring and cupped washer. Lift out the To remove and refit gear lever. Note the spring-loaded ball at the Remove oil level dipstick.

  • Page 138: Gearbox

    re-issue WSM. 124 Page4 Section E (Gearbox & Overdrive) --- - - A I : - 1•38" (35 MM) HOLES I I 1 - : I Ya" (3MM) DIA. A, DETAILS TO RT DAMPER ANO SPRING TO EARLY COVERS SPACING WASHERS ON EARLY COVERS Fl1, I b, top cover Rapier Sectional view of...

  • Page 139: To Remove

    WSM. 12-4 4th re-issue Section E (Gearbox & Overdrive) Page 5 REAR COVER Carefully tap out reverse selector shaft (64). Note To remove and refit the distance piece (66) at the rear of the selector fork. Remove speedometer pinion and bush. Carefully tap out the I st and 2nd and 3rd and 4th Remove rear mounting plate (two bolts and one nut).
  • Page 140 ..6360 EARL y ALPINE A. TO p COVER, MAINSHAFT, EA RL y CARS ER MAINSHAFT CIRCLIP AN D DISTANC E PIECE (SOME LAT R MOUNTING AND SPEEDO DRIVE. F l 1 , Exploded view f i ear bo x.

  • Page 141: Front Cover

    WSM. 114 re-issue Section E (Gearbox & Overdrive) Page7 FRONT COVER ASSEMBLY To dismantle and reassemble ( Figs. 3 and 4) To remove and refit (Fig. 3) Remove circlip (18) securing bearing (15) in front cover (5). The front cover assembly can only be withdrawn after the layshaft cluster (38) has been lowered into Press stemwheel assembly, complete with bearing, the bottom of the gearbox c:asing (1).
  • Page 142 4th re-issue WSM.124 Pages Section E (Gearbox & Overdrive) MAINSHAFT ASSEMBLY To remove (Figs. 3, Sa and Sb) Remove top and rear covers, selectors and front, cover. On early cars (inset B, Fig. 3) release lockwasher (36) and undo nut (37), securing bearing to shaft and remove distance piece (49) and speedo gear (48).
  • Page 143 WSM. 124 re-issue Section E' (Gearbox & Overdrive) Page To dismantle and reassemble (Figs. 3, Sc-Sf) Remove second speed wheel (28) and separate the baulk ring from the gear. Mark the baulk ring to ensure it is reassembled to the correct gear. Secure mainshaft in vice, using soft metal clamps.
  • Page 144 WSM.124 5th re-Issue Page 10 Section E (Gearbox & Overdrive) Check the baulk rings forconcentrlclty by "bluelng" test with the sleeve assembled to the hub with the the corresponding cone and rotating the ring upon shifting plates and clrclips In position. It.

  • Page 145: Reverse Wheel -To Remove And Refit

    re-issue WSM.124 Section E (Gearbox & Overdrive) Page 11 Poor Synchromesh REVERSE WHEEL When a gearbox is stripped to rectify a complaint To remove and refit (mainshaft and layshaft of this nature, the following items require particular removed) attention:- Withdraw rearwards, the reverse wheel spindle These must Replacement baulk rings.
  • Page 146 WSM.124 re-issue Section E (Gearbox & Overdrive) Page 12 1. Fit reverse wheel and shaft into casing (gears to the rear). 2. With the aid of thick grease position the bronze layshaft thrust washers (large one to the front) In the casing. 3.
  • Page 147 WSM. 124 Section E (Gearbox and Overdrive) Page Ila 6. Fit the rear bearing and press it right home. 8. Invert gearbox and insert layshaft spindle On early cars (Inset B Fig. 3) fit the spacer ( 49), through rear of casing, ensuring that the thrust speedometer gear (48), spacer (35), lockwasher washers at each end are correctly positioned.

  • Page 148: Overdrive

    WSM. 124 re-issue Section E (Gearbox & Overdrive) Page 13 OVERDRIVE The Laycock-de Normanvllle Overdrive unit The lower illustration In Fig. 7 shows the unit in gives an increase in propeller shaft speed of 24·67%, that overdrive. The cone clutch Is held forward by is, It has a ratio of 0·802 : 1.

  • Page 149: Control Of Overdrive

    WSM. 12-4 re-issue Page 14 Section E (Gearbox & Overdrive) CLUTCH CLUTCH PLANET PLANET THRUST SPRING BEARING CONECLUTCH WHEEL CARRIER ANNULUS SPEEDOMETER WHEEL OUTPUT SHAFT OIL SEAL (INTEGRAL WITH ANNULUS) SPIGOT SPEEDOMETER BEARING PINION ..:i:::> :> ... � PUMP SUNWHEEL UNI-DIRECTIONAL INLET...

  • Page 150: Lubrication And Maintenance

    6th re-issue WSM.124 & Page 15 Section E (Gearbox Overdrive) Self Cancelling Switch. (Fig. 13A) oil to the transmission and to servicing the unit. When the overdrive switch Is moved to the direct Any dirt or even lint from a wiping cloth that finds drive position, battery feed Is applied to terminal its way into a valve may cause serious difficulty.

  • Page 151: Adjustment Of Controls

    re-issue WSH. 124 Page 16 Section E (Gearbox & Overdrive) holding it centrally, give a tap, indenting two Overdrive does not release light grooves in the seating. Alternatively score the IMPORTANT-This calls for immediate attention. seating with a sharp pointed scriber (one score not reverse car, as selection of reverse in overdrive should be sufficient if deep enough).
  • Page 152 WSM. 114 3rd re-issue Section E (Gearbox & Overdrive) Page 17 Inserted, the solenoid plunger must be adjusted. Adjustment is effected by screwing the self-locking nut on the plunger in or out, with the plunger pushed into the solenoid as far as it will go. The solenoid spindle must be held against rotation by using a suitable spanner.
  • Page 153 WSM. 124 3rd re-issue Page Section E (Gearbox & Overdrive) A (Q' WARNIN G OVERDR IVE Brown/ 8fuc �II• · LIGHT SWITCH t&) : � : : � : . . . --.-;- ToA2 · · · -- -- - · ·1 Yel low /G ree n /""":°...

  • Page 154: Relief Valve

    4th re-issue WSM.12<4 Section E (Gearbox & Overdrive) Page 19 TESTING OIL PRESSURE engine stopped, move the overdrive switch into and out of the overdrive position ten or twelve Release the hydraulic pressure as previously times to release hydraulic pressure. described.

  • Page 155: To Remove From Gearbox

    WSM.124 re-issue Page 20 Section E (Gearbox & Overdrive) Fig. 16. Overdrive ready for fitting to gearbox (Later units are fitted with an external balance pipe and a plug replaces the breather) 2. Unscrew the valve cap and take out the spring eight ¼...
  • Page 156 WSM. 124 3rd l'e-issue Section E (Gearbox & Overdrive) Page 21 chamfered to enable the pump plunger to "ride" assembly to the o/s of the unit (adjacent to solenoid). on to the cam as the overdrive and gearbcx flanges Remove cover. come together.
  • Page 157 re-issue WSM.124 .trd Page '-2 Section E (Gearbox & Overdrive) torted. Ensure that the ball bearing is in good condition and rotates freely. Inspect the clutch springs for distortion or collapse. Inspect the teeth of the gear train for damage. If the sunwheel bush is worn, the gear will have to be replaced, since it is not possible to fit a new bush In service, because it has to be bored to the pitch...
  • Page 158 WSM.124 2nd re-issue Section E (Gearbox & Overdrive) Page 23 r;. - ..=- :3 1 - · ,.__ .. _____ Fl1. Exploded view Joint-Overdrive to cearbox adaptor. Rubber ring Relief valve. Ratchet Ball (Inset shows relief Front casing. free whee •• Pluncer valve usy.
  • Page 159 WSM.124 Page 24 Section E (Gearbox & Overdrive) using its small hole as a guide, drill out the broken inverted, second cage and collar. Screw second cage Into position. end of the Mills pin in the carrier. Note:-The drill size must be smaller than the new Treat each gear similarly and refit to the planet Mills pin to be fitted.
  • Page 160 re-issue WSM. 124 Section E (Gearbox & Overdrive) Page 25 Fig. 22. second Fitting cage Fit the planet carrier, pass the sunwheel splines into the open ends of the cone clutch member and Fig. 21, Fitting first cage fit the small clrclip at the forward end of the sunwheel.
  • Page 161 WSM. 114 re-issue Page 26 Section E (Gearbox & Overdrive) If new "O" rings are fitted to the pistons, use VLC. half, start the nuts on the studs, securing the two halves of the casing together and gradually tighten special tool. the nuts until the two faces meet.
  • Page 162 re-Issue WSM. 124 .fth Pace 27 Section E (Gearbox & Overdrive) OVERDRIVE UNIT-DIMENSIONS AND TOLERANCES Parts and Description Dimensions New Clearance New Pump · Plunger diameter (9·525-·100 -·020 mm.) +·0016" ( +·040 mm.) Bore for plunger in pump body t·+·0008" (9·525+·020 -·0002"...
  • Page 163 ws, ... 124 re-issue Section E (Gearbox & Overdrive) Page 28 Introduction points Relief valve - Summary of changes 1. Deep bore, (50·8 mm.) long valve, ¼" (4·76 mm.) i First production to 32/1450/7781 dla. ball. 2. Short bore , 1n' (32·54 mm ) long valve having ¼' I 32/1450/n82 to 32/1536/1843 (7·94 mm.) dla.

  • Page 164: Additional Information Adjustment Of Controls

    W.S.M. 12-4 Section E (Gearbox & Overdrive) Page 29 ADDITIONAL INFORMATION Adjustment of controls From late Series IV models onwards, the control is fitted with an adjustable stop pad. (See Fig. 26). Carry out all checks and adjustments, detailed on Page 16, as necessary.
  • Page 165 WSM.124 re-issue Section F (Front Suspension) Page I FRONT SUSPENSION SHOCK ABSORBERS CONTENTS Page No. GENERAL DESCRIPTION 2&32 TO CHECK AND ADJUST FRONT SUSPENSION DIMENSIONS AND SETTINGS -Tools and appliances -Preparation of vehicle ... 4&33 -Front wheel toe-in-To check -Setting of outer track rods ... -Ackerman angles (toe-out on turn)-To check ...

  • Page 166: Wsm.124

    WSM.124 4th re-issue Section F (Front Suspension) Pa g e 2 FRONT SUSPENSION SCREW THREADS OF THE. UNIFIED SERIES USED ON THIS UNIT GENERAL DESCRIPTION the lower face of the stub axle swivel. Serles I to IIIA Models This design obviates the necessity for a separate The front suspension Is of the coil spring and un­...

  • Page 167: To Check And Adjust Front Suspension Dimensions And Settings

    re-issue WSM.124 Section F (Front Suspension) Page 3 TO CHECK AND ADJUST FRONT SUS­ (b) The lower link inner taper fulcrum pin PENSION DIMENSIONS AND SETTINGS centre line and the unclerside centre of the taper hole in the end of the drop arm or The following settings and dimensions will require relay lever.

  • Page 168: Preparation Of Vehicle

    WSM.114 2nd re-issue Page 4 Section F (Front Suspension) PREPARATION OF VEHICLE When carrying out checks on the front suspension and steering dimensions, the following require­ ments must be met. It should be noted that item 5 entirely supersedes previous methods of obtaining the static laden condition.
  • Page 169 WSM.124 I st re-issue Page 5 Section F (Front Suspension) gap gauges to be positioned and suubseqently gripped in position by the lowering of the car. When these gap gauges are a slack fit, a small weight is placed on the rear end of the car to bring it on to the gap gauges.
  • Page 170 WSM.124 st re-issue Page 6 Section F (Front Suspension) Fig. 4. Plan view of steerage linkage ----,..,. : r · . • � "' I DIAL POINTER 1 : \ � : ! � • ' �' � •...

  • Page 171: Setting Of Outer Track Rods

    WSM.124 st re-issue Section F (Front Suspension) Page 7 the track is double the amount shown on the dial). Important Re-tighten the track rod end lock-nuts. With optical gauges or any type that does not require the road wheels to be turned through 180 °...

  • Page 172: Ackerman Angles (Toe-Out On Turn)-To Check

    WSM.11'4 Page 8 Section F (Front Suspension) It is recommended that the ball joint alignment Is may not necessarily be of equal length checked as a routine measure during the 12,000 when this has been done-ignore this. miles (19,200 km.) service. 10.

  • Page 173: Wheel Lock Angles-To Adjust

    re-issue WSM.124 Page 9 Section F (Front Suspension) To check Ackerman angles Prepare the car as described in "Preparation of vehicles", THIS IS IMPORTANT. Check the front wheel camber angle, front wheel alignment and correct as necessary. Set the front wheels in the straight ahead position on two turntable gauges.
  • Page 174 WSM.114 re-issue Page 10 Section F (Front Suspension) Fl1. 9. Clamping adaptor sleeve and gauge to spindle Fl1. Church/II camber checking gauge No. VLC.111L showlnf ¾ a typical readlnf positive camber Camber is POSITIVE if the bubble is in black figures, and NEGATIVE if In red figures.
  • Page 175 re-Issue WSM.124 Section F (Front Suspension) Page 11 CASTOR ANGLE READINGS the gauge to the tyre are clear of the normal bulge of the tyre, above the contact area of Vehicle loaded on to gap gauges tyre to ground. The designed castor angle given in the "General Turn the scale of the gauge on its pillar so that it is Data Section"...
  • Page 176 WSM.124 re-issue Section F (Front Suspension) Page 12 WHEEL CAMBER of the tyre, ensuring that the contact points of the gauge to the tyre are clear of the normal To check, using the Churchill camber gauge bulge of the tyre, above the contact area of (See Figs.

  • Page 177: Camber Ancle-To Adjust

    re-issue WSM, 124 Page 13 Section F (Front Suspension) Move the spirit level slide until the air bubble is Jack up the front of the car (using a block of wood between the jack and the front crossmember). central between the hair lines on the spirit level. Take the reading shown on the Castor and Steer­...
  • Page 178 re-issue WSM.114 Page 14 Section F (Front Suspension) must always be checked following a wheel camber re-set. After correcting the camber fi g ure by adjustment, the steering axis inclination angle should be again noted, to ensure that the stub axle Is not bent or damaged.

  • Page 179: To Remove And Refit Unit

    re-issue WSM.12 .. Section F (Front Suspension) Page 15 2. Remove greasers from both ends of each lower Place stands under the sidemembers of the under. link inner fulcrum pin. frame. 3. Fit up tool as illustrated in Fig. 21 making sure Remove the road wheels.

  • Page 180: To Dismantle And Reassemble Unit

    re-issue WSM.124 Page 16 Section F (Front Suspension) UNIT Remove the disc brake cal I per, (See Section K,Brakes). DISMANTLE AND REASSEMBLE (UNIT Remove the hub cap (2). ATTACHED CHASSIS) Remove the split pin from the castellated nut (3). To dismantle and reassemble the front hubs Remove the castellated hub retaining nut.
  • Page 181 re-issue WSM.124 Section F (Front Suspension) Page 17 The hub should then be fitted to the stub axle, the hub outer bearing roller race, washer and nut fitted, and the bearings adjusted. To adjust It is important that the following procedure be used.
  • Page 182 WSH.124 re-issue Section F (Front Suspension) Page 18 Fit the brake disc shield, steering arm, front hub Remove the road wheel. assembly and set the hub endfloat as previously Undo the bolts securing the steering arm, caliper described. and dust shield to the axle carrier. Note the position of any shims.
  • Page 183 WSM, 124 re-issue Section F (Front Suspension) Page To renew threaded cyebolt bush (Fig. 14) The threaded bush is externally knurled at one end, and pressed in with the knurling to the front on new cars. It follows that the bush must be pressed out towards the front of the trunnion assembly, I.e., the reverse way to which it went In, as otherwise the knurling will damage the parent bore of the...
  • Page 184 WSM.124 2nd re-issue Section F (Front Suspension) Page 20 Pass the long drift through the tapered hole in the upper yoke and Insert its splgoted end In the deep recess of the short drift. Carefully press out the swivel pin, ensuring that the assembly does not become tilted while pressing.
  • Page 185 WSM.12'4 re-issue Section F (Front Suspension} Page 21 TO REMOVE AND REFIT BOTTOM LINK Remove lower link eyebolt (25). (See Fig. 1-4) Disconnect stabilizer bar and remove four bolts securing bottom link fulcrum pin to the cross­ Remove front shock absorber ·(see "Stub axle member.
  • Page 191 (· Adaptor used to find centre of large end of taper holes :::, Line corresponding to /owe, link inner fulcrum pin centre :::, Outer fulcrum pin centre This plate Is moved over to take dimension 8 6·00* (152·'40 mm.) 5·9'4' (150·87 mm.) A = Idler lever 6·01' (152-65 mm.) A= Swing lever...
  • Page 192 WSM. ll4 Page 28 Section F (Front Suspension) 4-&A. I A . i- · 5 6 0 " D ·SOO"DIA� ===·--------- � :-tt- t - � - (¼.• B.S.F, ) 1/.4" U.N.F. Only Items f, 4 and 5 are required the models described this...

  • Page 193: Front Shock Absorber

    st re-issue WSM.124 Section F (Front Suspension) Page 29 FRONT SHOCK ABSORBER Armstrong Direct-Acting Telescopic Dampers are This piston rod guide forms a bearing for the piston fitted. rod, holds the rebound valve and drain tubes In position and contains the spring-loaded piston rod The body of the shock absorber Is telescopic and seal (D).
  • Page 194 WSM. 124 Section F (Front Suspension) Page 30 Grip the dirt shield firmly with the hands and On slow rebound strokes, fluid passes through a calibrated bleed groove In the face of the piston prime the shock absorber by working It up and down several times to expel the air.
  • Page 195 WSM. 124 re-issue Section F (Front Suspension) Pa g e 31 AuPPER AT TACHMENT D UST SHIEL D 1--�-lr--(REAR UNITS ONLY) PISTON ROD PISTON ROD SEAL PIS TON ROD GUIDE PORTS ANT I-FROTHING �:;..,;--- BAFFLE LREBOUNO VALVE TUBE PISTON VALVE ANTI-FROTHING ir - - -m:;::;:..
  • Page 196 re-issue WSM.124 Page 31 Section F (Front Suspension) RAPIER IV ALPINE IV A. 6·1in.(155mm) 5 ' 4 in.(137mm) B. 3·5 in. (89 mm) 2·75 in. (70 mm) C. 2·8 in. (71 mm) 3'5 in. (89 mm) Fl1, 26 unit Part sectional view of front suspension SERIES IV MODELS bearings together with similarly pre-packed ball joints on both ends of the two outer track...
  • Page 197 WSM. 124 / st re-issue Section F (Front Suspension) Page 33 l ..,. ---- '116( •. ,..) MATERIAL ¾ in. (6 mm.) MILD STEEL NUMBER REQUIRED 2 off � "(� ... ) 1½"(3-Su,.) gauges Fl1. 27. Details of front gap ALPINE IV.

  • Page 198: Stub Axles-To Remove And Refit

    st re-Issue WSM. 124 Page 34 Section F (Front Suspension) 2. Apply the handbrake, Jack up the front of the car and remove the front wheel. 3. Detach the steering arm from the stub axle by ·._/ withdrawing two bolts and washers, remove the brake caliper from the stub axle by withdrawing the remaining bolt and washer, suspend the brake caliper nearby without straining the...
  • Page 199 WSM.124 Section F (Front Suspension) Page 35 ® PRESS RAM NOSE CAP STEEL LINK SWIVEL BEARING SUPPORT 5889 TOOL pressing swivel bearing top link and "8" showing position of alignment slot when swivel bearing Fig. JO "A" from correct refitting STUB AXLE UPPER SWIVEL BEARING­...

  • Page 200: Stub Axle Lower Swivel Bearing-To Remove And Refit

    WSM. 124 Page 36 Section F (Front Suspension) beneath the press ram. eject the swivel bearing 4. Remove the bump rubber from the upper face by applying steady pressure and remove It from of the bottom link by detaching a nut and the press bed.

  • Page 201: Link Bushes-To Renew

    WSM.124 Page 37 Section F (Front Suspension) described under "Stub axle-To remove and refit" The Insulator Is fitted to the top of the front spring and then fed into the crossmember. earlier in this section but particular attention must be given to the followlng:- ii Compress the front spring until the fulcrum pin of the bottom link can be fitted to the After detaching the upper shock absorber...
  • Page 202 WSM. 124 Section F (Front Suspension) Page 38 ® ® PRESS RAH NOSE CAP MUSHROOM DRIVER �1 LINK BOSS FULCRUM PIN WISHBONE LINK SPECIAL WASHER AND BUSH LINK BOSS SUPPORT TOOL Ill· \� 5882 Fig. Illustrating method a( removing bushes from the links in a workshop press using special tool RG. 318 To remove link bushes (Fig.
  • Page 203 WSM. 124 Section F (Front Suspension) Page 39 © PRESS RAM NOSE CAP STEEL PACKING DRIVIN G TUBE LINK BUSH LINK BOSS WISHBONE LINK SLOTTED SUPPORT TUBE PACKING BLOCK Fig. 32 Illustrating method of fitting bushes to a link in a workshop press using special toal RG. 3/8 To flt link bushes (Fig.
  • Page 205 WSM. 124 2nd re-issue Section G (Rear Axle) Page I REAR AXLE· CONTENTS (23 Pqes) Page No. Hypold Bevel Spiral Bevel BEVEL PINION HOUSING OIL SEAL ... HUB OIL RETAINERS ... AXLE SHAFT -To remove and refit ... -To dismantle and reassemble 5 and 6 DIFFERENTIAL ASSEMBLY -To remove and refit...

  • Page 206: Wsm

    WSM.124 Pagel Section G (Rear Axle) REAR AXLE HYPOID BEVEL DRIVE when major attention to the unit is required. The GENERAL DESCRIPTION axle shafts are fully machined and supported at their A rear axle of the semi-floating type with detachable outer ends on ball bearings.

  • Page 207: Hub Oil Retainers

    WSM.12.C re-Issue Section G (Rear Axle) Page 3 HYPOID BE.VE.L DRIVE HUB OIL RETAINERS (Figs. I and 3) An oil splash guard (38), which consists of an outer ring overlapping an inner ring (37), is supplemented by an oil seal (39). The oil seal Is replaceable after removal of the rear hub (described in a later paragraph), and the three plain bolts and two dowel...
  • Page 208 F la. 3. of rear axle (Hypoid Exploded view Bevel Drive)
  • Page 209 2nd re-issue WSM.124 PageS Section G (Rear Axle) HYPOID BEVEL DRIVE Clamp the plate securing the shaft In the vice (Fig. 4). Remove split pin, loosen and remove hub retaining nut (50). Remove washer (49). Release vice, remove retaining plate and fit extrac­ tor tool (part of hub removing kit RG.
  • Page 210 WSM. ll<t re-issue Section G (Rear Axle) Page6 HYPOID BEVEL DRIVE Note: To refit As the Inner track of the hub bearing Is an Inter­ The lateral location of the hub bearing is controlled ference flt on the axle shaft It Is essential that by a sleeve on the Inner side of the bearing against bearings of the correct type are used.

  • Page 211: And

    5th re-issue WSM.124 Section G (Rear Axle) Page7 HYPOID BEVEL DRIVE Lift off differential assembly complete with crown NOTE:-Should it be found necessary to renew the wheel and bearings. Remove crown wheel and bearings which carry the differential assembly, the bearings taking care that outer races of bearings are old inner races may be withdrawn by means of the not interchanged, one side with the other.
  • Page 213 WSM.12.C re-issue Page9 Section G (Rear Axle) HYPOID BEVEL DRIVE Flt the outer bearing. The resultlng measurement, would be the thickness of shims to be added to the actual pinion at points A and B, to position the pinion relative to the crown Flt the coupling driver, washer and dummy nut.
  • Page 214 re-Issue WSM. 12-4 Pa1e 10 Section G (Rear Axle) HYPOID BEVEL DRIVE Rotating the pinion, tighten the nut progresslve1y. FAILURE TO ROTATE THE PINION MAY RESULT IN A FALSE PRE-LOAD. If the pinion becomes locked before the nut is tightened to the correct torque additional shims are required at point A.
  • Page 215 WSM.124 re-issue Section G (Rear Axle) Page HYPOID BEVEL DRIVE Fig. 6. Adjustment crown wheel and differential box bearinfs. Note also the shimming positions pinion adjustment DIFFERENTIAL UNIT-To adjust and refit bearings without shims, their inner faces abuttJng Note In Flf. 6, the shim and bearlnf thicknesses C, the differential box.
  • Page 216 re-Issue WSM.124 Page 12 Section G (Rear Axle) HYPOID 8E.VE.L DRIVE. If the actual bearing is thinner than the dummy the stylus against the heel of one of the crown wheel teeth, as nearly In line with the direction of tooth bearing, the amount must be added to the measure­...
  • Page 217 WSM.124 re-issue Section G (Rear Axle) Pa g e 13 RV,oJb ltvEl. bluvE TOOTH CONTACT CHART Tooth Contact Remedy Condition HEEL IDEAL TOOTH CON- (outer end) TACT evenly spread over profile, nearer toe than heel. (Inner end) Drive HEEL Move the Drive PINION HIGH TOOTH CON- (outer end) DEEPER Into MESH,...
  • Page 218 WSH.12 .. 2nd re-issue Section G (Rear Axle) Page 14 HYPOID BE.VE.L DRIVE. //-'\ �) ,,.._____ 1247P Fl1, 8. measure height of differential bearing surface plate Jack up rear of car so that the road wheels are Re-assembly is a reversal of the above operations. clear of the ground and support the underframe Bleed brakes (See Section K).
  • Page 219 re-issue WSM.124 Section G (Rear Axle) Page IS REAR AXLE BEVEL SPIRAi.. DRIVE GENERAL DESCRIPTION The complete differential assembly is detachable from the axle casing after removal of the axle shafts, A semi-floating rear axle with detachable taper­ when major attention to the unit is required. The mounted hubs incorporating a spiral bevel final axle shafts are fully machined and supported at their drive is fitted to some Rapier cars.
  • Page 220 WSM, 12.f Page 16 Section G (Rear Axle) � ·;;: "0 /@:; "ii \@· � � > ..• � \�= 'ts- "0 � �...
  • Page 221 re-issue WSM.124 Section G (Rear Axle) Page 17 Whenever a replacement oil seal is fitted, the Remove brake drum. outside of the cage should be coated with a liquid Release brake connections from rear of backing jointing compound before the seal is pressed into plate.
  • Page 222 re-Issue WSM.124 Page Section G (Rear Axle) To remove hub from axle shaft (after shaft Flt the split bush (part ofVLC kit RG.188A-1) to the removal) solid ring. Note. It Is not necessary to dismantle the tool to fit the split bush. The bearing may be Attach retaining plate (part of hub removing kit left resting on the tapered portion of the axle shaft RG.188) to the four wheel studs, using the existing...
  • Page 223 lsc re-Issue WSM.124 Section G (Rear Axle) Page 19 refit". It can be checked that this compression DIFFERENTIAL UNIT-To dismantle and has been obtained by attempting to rotate the reassemble (See Fig. I 0) Inner splash guard which Is Interposed between the ring and the bearing Inner race.
  • Page 224 WSM.124 Page 20 Section G (Rear Axle) must be renewed as a pair, as is the case with be removed from the pinion by means of an arbor all bearings of this type. It is not permissible press using a suitably shaped drift block to support to renew either inner or outer portion the inner race, or using the VLC Hand-press RG.
  • Page 225 WSM. 124 Section G (Rear Axle) Page 21 COUPLING NUT WASHER FRONT BEARING SHIMS 'C' DISTANCE TUBE REAR BEARING REAR BEARING NOTE : NO DIS­ TANCE WASHER OR SHIMS '8' CENTRE JIG 1077.P. Fig. Fig. 12. Measure with distance washers and feelers Jigs used in adjustint bevel pinion bearing preload and bevel pinion in relation to axis of crown wheel V.
  • Page 226 WSM, 124 Section G (Rear Axle) Page 22 It is essential that, of the three apertures suitable length of tubing to drive the appropriate dummy bearing Inwards. the rear face of the oil seal, one should be at the top, or "12 o'clock" position. Having obtained the correct adjustment, measure This completes the assembly and adjustment of the the gaps between the outer faces of the dummy...
  • Page 227 WSM.124 Section G (Rear Axle) DIFFERENTIAL UNIT-Measurement of A dial indicator gauge must be used; the body of which Is secured to the differential housing. bearings The reading Is then taken off the thrust side of a This requires great accuracy and may present a crown wheel tooth, by means of moving the crown little difficulty.
  • Page 228 WSM.124 re-issue Section H (Rear Suspension) Page I REAR SUSPENSION CONTENTS ( 1-4 Pas••) Page No. REAR SUSPENSION -General ... REAR SPRING -To remove -To refit -To dismantle -Examination -To rebuild -To check rear spring camber SHOCK ABSORBERS Alpine -Servicing ... -Testing -Topping up the fluid Rapier...

  • Page 229: Rear Suspension

    WSM, 114 5th re-issue Section H (Rear Suspension) Pagel REAR SUSPENSION Remove the front pivot pin in a similar manner to GENERAL the lower shackle pin. The rear suspension is by means of two semi-elliptic springs which are secured to the rear axle casing. The spring is now free to be taken away.
  • Page 230 WSM.12 .. re-issue Section H (Rear Suspension) Pa g e 3 · 3 6 - • .· �J9 3 6 _ � �� 28�0 27� �ll � �'3� 4-864 Fig. rear eccentric bush) Exploded view of Rapier suspension (without 1 Rear spring. Pivot Pin Main leaf.
  • Page 231 WSM. 12 .. re-Issue Page 4 Section H (Rear Suspension) 38 - � ) 6 - � 3 9 �1_--� 35:::: 3 6 -- � � 31 - � 3 6-� , JS� � 34�- �38 Fig. 2. eccentric bush) Exploded view of rear suspension (with Rear spring.
  • Page 232 WSM, 124 re-issue Section H (Rear Suspension) Page 5 Fis. 3. A/pine Series Exploded view of I and II rear suspension. -��- ;::{--=- '� � r spring. eaf. 3 Spring bush. 4 Bund e clip. 26 Shack 5 Rubber lining. 27 Shack bush.
  • Page 233 WSM.124 4th re-Issue Section H (Rear Suspension) Pa g e 6 ...__,/ 6699 Fig. 1. Components of the suspension Alpine rear 18. PIVOT PIN REAR SPRING MAIN LEAF 19. WASHER BUSH, SPRING EYE 20. SHACKLE PINS WASHER 21. WASHERS 22. SHACKLE ASSEMBLY 23.

  • Page 234: Examination

    4th re-Issue WSM.124 Section H Suspension) (Rear Pa1e7 ± Examination A tolerance of In. (·8mm) must not be ex­ ceeded. To ensure that this is maintained, the Clean the spring leaves thoroughly using paraffin. spring should be scribed as shown at (A) In Fig. '4 Check thrust buttons for excessive wear and, If before fitting.

  • Page 235: Shock Absorbers

    4th re-issue WSM.12-41 Section H (Rear Suspension) Page8 SHOCK ABSORBERS ALPINE The suspension is controlled by Armstrong hydraulic Before carrying out the check, work the shock absorber through six to eight strokes to expel any shock absorbers, which are of the double-acting self-regulating type.
  • Page 236 re-Issue WSM.12-4 Page9 Section H (Rear Suspension) 1 2 . 19 20 2 J Fig. 5. Armstrong hydraulic shack absorber I Arm. 14 Compression or bump cylinder. 15 Valve screw. 2 Gasket. 16 Valve screw compression washer. 3 Shakeproof washer. 4 Lid screw.

  • Page 237: Construction

    WSM.12,f 3rd re-issue Page 10 Section H (Rear Suspension) SHOCK ABSORBERS RAPIER Girling Direct-Acting Telescopic Dampers are Any fluid which exudes past the guide bearing is titted. prevented from escaping further by the seal and a port below the seal allows fluid to return into the The body of the shock absorber is telescopic and reservoir tube via a closed circuit drain tube fitted is mounted more or less vertically between the...
  • Page 238 WSM.12-4 I st re-issue Page II Section H (Rear Suspension) AT REST COMPRESSION EXTENSION DIRT SHIELD PISTON ROD OIL SEAL PISTON ROD GUIDE PRESSURE / TUBE FLUID UNDER RESERVOIR PR�S�URE RESERVE TUBE BASE VALVE 376S FLUID UNDER PRESSURE Fl1. 6. Diagrammatic sections of telescopic shock absorbers.

  • Page 239: Operation

    WSM.124 Section H (Rear Suspension) Page 12 of the cylinder. If, however, the downward move­ obtained by carrying out the following check:­ ment of the piston Is a fast one the slotted sleeve Remove the shock absorber from its mounting. valve also at (B), controlled by the strong laminated Place the shock absorber vertically in a vice, spring washer will be opened.

  • Page 240: Testing

    WSM. 124 Section H (Rear Suspension) Pa1e13 the piston is moving relatively towards the foot valve (13) fluid pressure opens the piston valve (21) against the coil spring load and fluid passes through the ports (7) in the piston valve from the lower half of the cylinder (A) to the upper part of the cylinder (B).
  • Page 241 WSM.124 Page 14 Section H (Rear Suspension) Grip the dirt shield firmly with the hands and however, the resistance Is slight, erratic or free prime the shock absorber by working it up and movement cannot be eliminated by priming, down several times to expel the air. then the shock absorber should be changed.
  • Page 242 re-issue WSM. 124 Section J (Steering) Page 1 STEERING GEAR RAPIER & ALPINE CONTENTS Page No. STEERING COLUMN COWLING -Description --: To remove and refit DIRECTION INDICATOR SWITCH -Description -To remove and refit OVERDRIVE SWITCH HORN RING, COVER AND MOTIF ASSEMBLY -Description -To remove and refit STEERING WHEEL...

  • Page 243: Section J (Steering)

    WSM.124 4th re-issue Page 2 Section (Steering) STEERING GEAR is returned to the straight ahead position, a pawl STEERING COLUMN COWLING on the cancelling ring operates a trip mechanism Description on the switch which cancels the flasher. For The plastic cowling Is made in two halves. wiring details, see Section N.

  • Page 244: To Remove And Refit

    WSM. 124 re-issue Section J (Steering) Page 3 HORN RING, COVER AND MOTIF STEERING WHEEL ASSEMBLY To remove Description Remove horn ring assembly as previously described. The horn ring consists of a circular central plate Undo centre securing nut using special tool with two spokes, to which the outer ring is joined.
  • Page 245 WSM.124 Page4 Section J (Steering) 5301 Fir, 1. Exploded view of"F" type steering unit Felt bush and washer. Steering box. Rocker shaft bush. Double coil spring. Outer column. Oil seal. Damper button. Paper gaskets 0olnt washers). Drop arm (swing lever). Guide roller.
  • Page 246 re-issue WSM.124 Section J (Steering) PageS To remove from car-(Alplne) 13. Remove the drop arm from Its spline using special tool RG.198. (Left-hand drive cars only) 1. Disconnect and remove the bonnet which is H. Lower the jack. attached to its hinges by eight bolts. 15.
  • Page 247 WSM, 124 Page6 Section J (Steering)
  • Page 248 WSM.124 re•issue Section J (Steering) Page7 5. Check the alignment of the steering column 14. Jack up the front of the car and remove the clip relative to the upper column bracket. If nut and tab washer securing the drop arm to there Is malalignment, remove the steering the rocker shaft.
  • Page 249 WSM.124 Section J (Steerin1) Pages 3. Refit the steering column grommet in the hole 7. Jack up the front of the car and remove nut and tab washer securing the drop arm to the in the bulkhead. rocker shaft. 4. Loosely attach the steering column to the dash and bulkhead brackets, and bolt the steering 8.
  • Page 250 re-issue WSM. 124 Section J (Steering) Page9 cannot be secured to the upper column release the twelve balls (20), from the upper bracket without being strained into place, track (21), which should be immediately shims should be inserted between the steering recovered.
  • Page 251 4th re-issue WSM.12-4 Page 10 Section J (Steering) BURMAN TELESCOPIC STEERING To pre-load the inner column bearings UNIT 8. Using a feeler gauge, measure the gap between the bottom face of the outer column and the A Burman telescopic steering unit Is similar in upper face of the steering box.
  • Page 253 WSM.124 Page 12 Section J (Steering) Fig. 4. of the telescopic The upper portion steering unit away section. OUTER COLUMN. BALL BEARING RACE. INNER COLUMN. SPRING AND CIRCLIP. EXPANDER BOLT. DOWEL. SPLINED EXTENSION PIECE. STEERING WHEEL NUT RUBBER BUNG. SPLIT NYLON BUSH. CROSS DOWEL.
  • Page 254 WSM. 124 Section (Steering) Page 13 3. Remove the lower steering column cowling Withdraw the overdrive switch from the upper 3. cowling and disconnect at the snap connectors. from the upper by withdrawing three screws, disconnect the cable from the Lucar connector Refitting Is the reverse of the removal sequence.
  • Page 255 WSM. 124 Page 14 Section (Steering) (Fig. column (2) and limits its upward and downward To remove and refit travel to predetermined amounts. The lower end Remove the horn ring assembly (8) from the is slotted and has an internal taper to accommodate steering wheel centre (9) see under "Horn the cross dowel and male taper of the expander Ring Assembly-To remove and refit".
  • Page 256 st re-issue WSM. 124 Section J (Steering) Page 15 To dismantle and reassemble (Fig. 4) The splined extension piece (4) Is fed into the swaged portion of the inner column (2) The dismantling and reassemble sequences for the so the groove aligns with the dowel hole. telescopic steering unit is similar to the rigid unit concerning the steering box which is fully described A new dowel is pressed into the inner...
  • Page 257 WSM. 114 I st re-issue Page 16 Section J (Steering) Remove the outer and centre track rods from the front and rear ends of the relay lever by discarding the split pin and removing the castellated and self locking nuts respectively from the tapered ball pins and using a suitable extractor RG.

  • Page 258: Steering Relay Lever Assembly

    WSM. 124 Section (Steering) Page 17 4. Re-assembly is the reverse of the dismantling A­ sequence but particular attention must be given to the following:- (i} Ensure the sealing ring is in good condition and recessed correctly in the relay lever groove.

  • Page 259: To Remove And Refit

    WSM. 12 .. Page 18 Section J (Steering) (v) Fit the wider sealing ring around the Series I to IIIA Models washers on the lower end of the pin. The bush bearings used in this relay lever assembly are of the" Clevite" type which require periodical (vi) The pin of the relay lever Is fed into the lubrication.
  • Page 260 WSM. 124 re-issue Section K (Brakes) Page I BRAKES CONTENTS Page No. Alpine Rapier GENERAL -Maintenance -brake adjustments -brake fluid level. .. FRONT BRAKES -Brake pads-to remove and refit -Calipers-to remove and refit ... -to dismantle and reassemble -Splash cuards-to remove and refit -Discs-run out -to remove and refit REAR BRAKES...

  • Page 261: Maintenance

    WSM.124 re-issue Pagel Section K (Brakes) BRAKES-ALPINE GENERAL Chock up one of the front wheels, release the handbrake and jack up both rear wheels. Girling type disc brakes are fitted to the front Lock the shoes by means of the adjusters wheels and Girling drum brakes to the rear (arrowed In Fig.

  • Page 262: Front Brakes

    re-Issue WSM.114 Pagel Section K (Brakes) ALPINE. The addition of fluid will be required at regular hoses-to remove and refit". intervals due to the repositioning of the front To check for leaks, apply a firm pressure to the wheel pistons as a result of friction lining wear, brake pedal whilst an assistant examines the units, but a rapid fall in fluid level would indicate a leak pipes, hoses and fittings.
  • Page 263 WSM, 124 7 rh re-Issue Section K (Brakes) Pa g e<f ALPINE To remove and refit (Figs. 2 and I. ·Apply the handbrake, jack up the front of the car and remove the road wheel. 2. Withdraw the two brake pads from the caliper and when fitted, the anti-rattle springs and anti-squeal shims by removing the two retain­...

  • Page 264: Calipers-To Remove And Refit

    WSM. 114 re-issue Pages Section K (Brakes) ALPINE CALIPERS To remove and refit Apply the handbrake, jack up the front of the car and remove the road wheel. Detach the caliper from the stub axle carrier by withdrawing two bolts and identifying any packing washers, shims...

  • Page 265: Splash Guards

    WSM.124 re-issue Page6 Section K (Brakes) ALPINE Remove the sealing rings (6 and 13) by inserting Serles I models* and on all Serles II models, the splash guards are retained on the stub axles by a screwdriver under the rings and prising them distance pieces and are secured to the lower bosses out, taking great care not to damage the locat­...

  • Page 266: Discs-Run Out

    WSM. 124 re-issue Page7 Section K (Brakes) ALPINE Series I models only Ensure that any packing washers and shims are refitted to their original positions. Later Series I* and Series II models Immerse the distance piece in boiling water and while still hot tap the distance piece onto the stub axle with a tubular drift until It clamps the splash guard to the stub axle carrier.

  • Page 267: Rear Brakes

    WSM. 12-t re-issue Page 8 Section K (Brakes) ALPINE (iv) The disc run-out is checked, see under (vi) Set the hub end float, see under "Front "Disc Run-out". When the run-out is hubs-To adjust" In Section F. greater than the specified figure, the disc (vii) When a replacement disc is fitted to can be repositioned on the hub in an Serles I and II models position the caliper...
  • Page 268 WSM. 124 3rd re-issue Section K (Brakes) Page9 ALPINE Fig. 5. Exploded view of rear brake RETURN SPRING RETAINING PLATE PISTON RETURN SPRING WEDGE SEAL 3 ADJUSTER 'LINK ADJUSTER LINK CYLINDER BODY DUST COVER CLIP ADJUSTER HOUSING BLEED SCREW DUST COVER LEAF SPRING DUST COVER 6 HANDBRAKE LEVER...

  • Page 269: To Reline 10

    re-issue WSM.124 Page 10 Section K (Brakes) as near as possible to the rivet being removed. Lay the shoes on a bench with the "toe" of one shoe ALPINE Repeat for the other shoe. adjacent to the "heel" of the other. Fit the return springs (I and 2) to the underside of -4.
  • Page 270 WSM. 124 re-issue Section K (Brakes) Page ALPINE gap between the lining and the brake shoe of each lining should be slightly chamfered after platform. fitting to the brake shoe. Refit the brake shoes as previously described. No attempt should be made to reline the brake pads It is not necessary to chamfer the heel and toe of the on the front brakes.
  • Page 271 WSM. ll<C re-issue Section K ( Brakes ) Page 12 ALPINE To refit (See fig. 5) "Bleeding the system". Insert the neck of the wheel cylinder (15) through To dismantle (See fig. 5) the slot in the backplate. Remove the wheel cylinder from the backplate as fit the distance piece ( 19) between the cylinder neck previously described.

  • Page 272: Handbrake Anti-Rattle Springs

    4th re-issue WSM.124 Section K (Brakes) Page 13 ALPINE HANDBRAKE ANTI-RATTLE SPRINGS B9110954, the clips are positively located on the adjustable side by a distance piece and are welded The anti-rattle springs shown in Fig. 7A must be in onto the rod on the non-adjustable side. On cars equal tension, otherwise binding may occur on one built prior to this chassis number, the dimensions side.
  • Page 273 4th re-issue WSM.124 Page 14 Section K (Brak•) ALPINE (5) and by fluid pressure In the drilling at the back To remove of the valve stem (7). As the plunger continues to Disconnect the pressure an d feed pipe* unions from the cylinder collecting the brake fluid In a suitable move up the bore, fluid Is forced through the pipe llne to the wheel cylinders.
  • Page 274 4th re-issue WSM.124 Pa1e 15 Section K (Brakes) ALPINE Remove the master cylinder from the bulkhead by use petrol, paraffin, trlchlorethylene or any other easing It forward. Note the position of the packing . similar agents to wash the parts. To refit Replace the valve seal (4) sc that the flat side Is Refitting is a reversal of the above instructions.
  • Page 275 WSM. 12-t 4th re-issue Section K (Brakes) Page 16 To remove (See Fig. 9) while holding the sleeve hexagon to prevent the hose from rotating. Disconnect the metal fluid pipe by unscrewing the union nut from the hose union. When fitted, slide the hose locating plate onto the support bracket so the plain hole is on the feed Hold the hexagon of the flexible hose end sleeve at pipe side;...
  • Page 276 re-issue WSM.124 Section K (Brakes) Page 17 BRAKES - RAPIER wheels to prevent the car from rolling, and release GENERAL the handbrake. Lockheed PM34 disc brakes are fitted to the front wheels and Lockheed drum brakes to the rear Remove the nave plates and jack up one rear wheel wheels.
  • Page 277 6th re-issue WSM.11-4 Page 18 Section K (Brakes) RAPIER Repeat for the other wheel. kept within _ I n. (13 mm) below the filler cap orifice. Never fill completely since the expansion Normally adjustment of the rear brakes will auto­ of fluid In hot weather may cause the brakes to matically adjust the handbrake.
  • Page 278 WSM.12-4 5th re-issue Section K (Brakes) Page 19 RAPIE.R FRONT BRAKES After negotiating a ford, water splash, or when DESCRIPTION driving on flooded roads, it may be necessary to Each brake consists of an 11 in. (279 mm) diameter dry out the brakes to restore full braking power by a high quality cast iron disc which is attached to and It Is also few light applications of the brake pedal.

  • Page 279: To Dismantle And Reassemble

    re-issue WSM.12 .. Page 20 Section K (Brakes) RAPIER that the pressure plate extends beyond she CALIPERS friction lining along that edge (see Fig. 13). If the rubber sealing rings (Item 6, Fig. 14) are worn Enter the pads, lower ends first, into the or damaged, they should be replaced Immediately.
  • Page 280 WSM.12-4 re-issue Section K (Brakes) Page 21 RAPIE.R EARLY CONDITION CALIPER BODY ( MOUNTING HALF} CALIPER BODY (RIM HALF) BLEED SCREW SPLIT PIN STEADY SPRING PISTON SEALING RINGS DUST SEALS DUST SEAL RETAINERS 9(a) PISTON (MOUNTING HALF) 9(b) PISTON (RIM HALF) BRAKE PAD ASSEMBLIES DISC LATER CONDITION...
  • Page 281 WSM,124 4th re-Issue Section K (Brakes) Page RAPIE.R 15. Two types of seal and retainer assemblies have been fitted In conjunction with this caliper. The earlier type of seal has a rectangular section, whilst the later type Is " U" sectioned. To fit the earlier type, the seal must first be positioned In the recessed portion of the cylinder bore.
  • Page 282 WSM.124 re-issue Page 23 Section K (Brakes) RAPIER when tab washers are used on the bolts, Revolve the disc and check the Indicator reading; do NOT turn up the tabs until AFTER the maximum reading on the gauge should not the disc run-out has been checked.
  • Page 283 WSM. 124 4th re-issue Section K (Brakes) Page 24 RAPIER Each lever (6) is retained In Its cylinder body by a BRAKE SHOES pin (7). When the handbrake is applied, the linkage It will be noted that the brake shoe linings are pulls on the levers which pivot about their pins and off-set on the platforms to which they are attached.
  • Page 284 WSM.124 4th re-Issue Section K (Brakes) Page 25 RAPIER turning the "mlcram" adjuster anti-clockwise to To reline the full extent using a screwdriver. (See Fig. 10). It Is strongly recommended that advantage be taken Remove the brake drum and distanc� piece, when of the Factory Reconditioned Service Unit Scheme fitted, from the axle flange by withdrawing a whereby replacement brake shoe and lining assem­...
  • Page 285 WSM.124 re-issue Section K (Brakes ) Page 26 RAPIER Thoroughly degrease the shoes. WHEEL CYLINDERS (See Fig. 16) Each wheel cylinder consists of a die-cast aluminium Inspect each shoe carefully for damage and body (11 ) containing two pistons. The outer piston cracks.
  • Page 286 WSM.124 re-issue Section K (Brakes) Page 27 RAPIER Push out the handbrake pivot pin (7) and remove Fit the rectangular sectioned seal (4) Into the groove the lever (6). in the outer piston. With the bleed screw ( I 0) In position, remove the Insert the inner piston (5) into the wheel cylinder Inner piston (5) by applying gentle air pressure to body closed end first and with the longest slot In the...
  • Page 287 ,.,.. 5th re-Issue WSM.124 Sutlort K ( ..) RAPIER MASTER CYLINDER The master cylinder can now be removed by easing It forwards. Description (See fig. 18) To refit The master cylinder Is situated under the bonnet on the bulkhead, Immediately In front of the brake Refitting Is a reversal of the above instructions.
  • Page 288 WSM.124 re-issue Page 29 Section K (Brakes) RAPIER Fig. 18. Moster Cylinder 1. FILLER CAP 8. WASHER 2. WASHER PISTON 3. MASTER CYLINDER BODY 10. SECONDARY CUP 11. PUSH ROD ASSEMBLY 4. •CHECK VALVE 5. RETURN SPRING 12. CIRCLIP 6. SPRING RETAINER 13.
  • Page 289 WSM.124 re-Issue Section K (Brakes) Page 30 RAPIER Hold the hexagon of the flexible hose end sleeve at Top up the reservoir to Its correct level of ½ In. one side of the support bracket and unscrew the (13mm) below the tiller cap orifice, and refit the locknut from the other side to release the hose master cylinder to the car as previously described.
  • Page 290 WSM.124 Section K (Brakes) Page 31 GIRLING VACUUM SERVO UNIT The Girling Vacuum Servo Unit Is Installed In the from the Inlet manifold to temporarily communi­ brake hydraulic system between the master cylin­ cate with the second side of the piston (5) In the der and the brake assemblies on the roadwheels vacuum cylinder (19) thus vacuum on both sides with master cylinder outlet pipe connected to the...
  • Page 291 WSH.124 Section (Brakes) Page 32 Cross section Se1YO Fl1. 20. view of Girllni Vacuum Unit END COVER GASKET TRANSFER TUBE PISTON BACKING RING PISTON ROD PISTON SEAL VACUUM CYLINDER PISTON SEAL RETAINER CONTROL PISTON SPRING PISTON VACUUM INLET PISTON RETURN SPRING VACUUM VALVE CONSTANT VACUUM BEARING BUSH...
  • Page 293 WSM.124 re-issue Section K (Brakes) Page 34 Remove the cover and transfer pipe (17) Refitting Is the reverse of the removal from the valve chest (26) by withdrawing sequence but particular attention must be four screws and washers. given to the following. All seals must be renewed and lubri­...
  • Page 294 WSM.124 Section K (Brakes) Page 35 air valve (31) is away from the two xiii Position the end cover ( 15) with a new securing screws inside the valve chest gasket (I) on top of the piston (5) and press down, taking care the piston rod (26).
  • Page 295 WSM.124 Page 36 Section K (Brakes) TESTING EQUIPMENT Test 2 Connect the vacuum pipe from the inlet To make comprehensive tests, of the vacuum servo manifold to the vacuum port. unit, requires complex and expensive equipment and this kind of testing is outside the capacity of Connect the fluid inlet and outlet pipes to many Service Workshops.
  • Page 296 WSM.124 Page 37 Section K (Brakes) Test 3. It Indicates leaking gaskets, air valve or outlet and test. If creeping of the pedal Is rubber grommet. Clamp the vacuum hose evident when the hoses are clamped and and repeat Test 3. If satisfactory, the non­ the pedal Is solid when the master cylin­...
  • Page 297 WSM. 124 Page 38 Section K (Brakes) FAULT CAUSE ACTION Slow action of servo unit Swollen rubber grommet. I Fit new parts from Service Kit. ii Blocked filter or restricted ii Examine air filter element air inlet. and renew if necessary. Renew vacuum hose.

  • Page 298: Air Filter

    WSM.12-4 Section K (Brakes) Page 39 THE LOCKHEED VACUUM SERVO UNIT GENERAL Lift the air valve (item 20, Fig. 23) off its seat and blow compressed air at low pressure into The purpose of the vacuum servo unit is to lower the filter chamber.
  • Page 299 WSM. 124 Page 40 Sect" ion K (Brakes) ./4 1 / GZ o/2 1) Fis. 22 Se view rvo unit-exploded...
  • Page 300 WSM.124 Section K (Brakes) Page 41 Fig. 23. Sectional view of the servo unit Annotation for Figs. 22 and 23 27. GASKET I. RUBBER ELBOW 1-4. RETURN SPRING 28. SPRING RETAINER 2. CLAMPING RING IS. BOLT 29. SPRING 3. CLAMPING SCREW 16.
  • Page 301 WSM. 12,t Page 42 K (Brakes) Section (a) The lower pressure line from the master Light pressure on the foot pedal cylinder to chamber V. CONDITION A With very light pedal pressure, no servo assistance (b) The high pressure line beyond hydraulic piston is given.
  • Page 302 VACUUM CONNECTION TO CTION MANIFOLD INDU VACUUM CONNECTION TO CTION MANIFOLD INDU BOOSTED H;DRAULIC PRESSURE T o WHEEL CYLINDERS RAULIC LINE FROM MO A STER CYLINDER VACUUM CONNECTION TO INDU CTION MANIFOLD BOOSTE D HYDRAULIC PRESSURE TO WHEEL CYLINDERS HYDRAULIC LINE FROM MASTER CYLINDER 7267...
  • Page 303 WSM. 124 Page 44 Section K (Brakes) Pressure on the foot pedal released Remove the servo unit from the car as pre­ viously described. (CONDITION A) 2. Hold the unit in a vice by the slave cylinder The pressure drop at the master cylinder results body (26), taking care not to over-tighten.
  • Page 304 WSM. 124 Page 4S Section K (Brakes) Inside diameter 0·688-0·690 in. 13. Bend back the tabs of the locking plates ( 16) and remove the four bolts (IS) securing the (17·-48--17·53 mm.) vacuum shell (18) and abutment plate (17) to Outside diameter 0·9735-0·9745 in.
  • Page 305 WSM. 124 Page 46 Section K (Brakes) 15. Place the control valve diaphragm assembly Place the abutment plate (17) in position Inside the vacuum shell (18) and secure, using (23) on the valve housing (24), with the narrow two locking plates (16) and four bolts (15). stem Inserted Into the piston (11) and the The four bolts should be tightened to a torque screw holes In the periphery of the diaphragm...

  • Page 306: Handbrake Cable

    WSM.124 st re-issue Page 47 Section K (Brakes) HANDBRAKE CABLE Alpine Series Rapier Series IV Models onwards The long handbrake cable from the driver's hand­ brake lever to the compensating lever mounted on the rear axle is nylon lined and requires no period­ cal lubrication, thus no greaser is provided.
  • Page 307 1st re-issue WSH. 124 Page 48 Section K (Brakes) Handbrake operation (Fig. 26) Early Rapier Series IV Models To improve handbrake operation on early Rapier Series IV Cars an extension is fitted to the wheel cylinder levers and the forkends of the handbrake cables are attached to these lever extensions.
  • Page 308 WSM. 124 Section K (Brakes) Page 49 SELF ADJUSTING REAR BRAKES DESCRIPTION (Fig. 27) Later Rapier Series IV Cars and onwards are equipped with self adjusting rear brakes which will maintain a specific brake shoe clearance. The self adjusting action is effected as the brakes are released whether foot or hand operated.
  • Page 309 WSM. 124 Page 50 Section K (Brakes) 4. Apply a rubber band to the wheel cylinder to retain the tappet and adjuster wheel In the head of the piston; identify the four holes in the brake shoe webs accommodating the two pull off springs.
  • Page 310 WSM. 124 Page 51 Section K (Brakes) WHEEL CYLINDERS To dismantle and reassemble I. Clean off all road dirt and when working on two wheel cylinders, identify them left or right To remove and refit hand. I. Remove the brake shoes from the back plate, 2.

  • Page 311: Tyres And Wheels

    WSM.124 re-issue Section L (Tyres & Wheels) Page 1 TYRES AND WHEELS CONTENTS Page No. TYRE EXAMINATION TYRE AND WHEEL BALANCE PRESSED STEEL WHEELS WIRE WHEELS CHANGING POSITION OF TYRES NYLON TYRES WHEEL ALIGNMENT WHEEL TRIM DISCS...
  • Page 312 WSM.12-4 2nd re-issue Page 2 Section L (Tyres & Wheels) TYRES AND WHEELS TYRE EXAMINATION moving parts may even render the car more sensitive to unbalance. Tyres should be examined regularly for:­ Rebalancing of tyre and wheel assemblies should be lnflatlon pressures.
  • Page 313 WSM.124 4th re-issue Section L (Tyres & Wheels) Page 3 Tightening, Wheel nuts should be free on their Hub nuts on the right-hand side of the car are studs. When fitting a wheel all the nuts should removed by turning them clockwise, those on lnltlally be screwed up lightly, ensuring that their the left-hand side by turning them anti-clockwise.

  • Page 314: Wheel Alignment

    WSM.124 4th re-issue Page 4 Section L (Tyres & Wheels) NYLON TYRES It is very important to ensure that the tapers are clean before the wheel is fitted. If necessary, the Nylon tyres may develop temporary flatting after tapers should be emeried and polished to remove standing for some time and cooling off, following a all dirt and rust;...

  • Page 315: Electrical Equipment

    WSH.12-4 re-issue Section N (Elec. Equip.) Page 1 ELECTRICAL EQUIPMENT CONTENTS Page No. BATTERY -Maintenance -Charging -Preparing new battery COIL (Refer to Distributor) CONTROL BOXES 11 & 14A -Settings ... 12 & 14B -Servicing 12 & 14B HEADLAMP DIRECTION INDICATOR SIGNALS AND FLASHER DISTRIBUTOR -Maintenance...
  • Page 316 re-issue WSM. 114 Page 2 Section N (Elec. Equip.) ELECTRICAL SYSTEM Years of experience have proved Lucas electrical equipment recommended is available. Further, equipment to be very realiable and efficient. It will be seen that special equipment Is needed for Periodical maintenance, however, must not be dismantling and reassembling some units of the...

  • Page 317: Section N (Elec. Equip.)

    re-issue WSM.124 Section N (Elec . Equip.) Page 3 water from being spilled over the top of the is very dirty, or contains small particles in battery. suspension, it is possible that the plates are in a bad condition. Distilled water should always be used for topping-up.
  • Page 318 WSM. 124 2nd re-issue Page 4 Section N (Elec. Equip,) If the level of the electrolyte Is so low that a with the tops of the separator guard by the addition hydrometer reading cannot be taken, of distilled water. Re-charge rates are as follows:- attempt should be made to take a reading after BT 7A Batteries (43 ampere-hour) 4 amps.
  • Page 319 re-issue WSM. 124 · Section N (Elec. Equip.) Page S periods. If, however, the temperature of any cell To obtain specific vol. acid rises above maximum quoted: gravity 1·835 S.G. (corrected to 60 ° ° (corrected to 60 ° ° °...

  • Page 320: Maintenance

    WSM.124 re-issue Page6 Section N (Elec. Equip.) t he battery is fully charged. Such a freshening distilled water. Check the specific gravity of the char g e should last for no more than 4 hours, at the acid at the end of the charge; if 1 ·260 acid was used normal recharge rate of the battery.
  • Page 321 WSM.124 I st re-issue Section N (Elec. Equip.) Page 7 Clip the negative lead of a moving coil type Withdraw the commutator-end bracket (1) voltmeter, calibrated 0-20 volts, to one from the yoke (6). generator terminal and the positive lead to a Lift the driving-end bracket and armature good earthing point on the yoke.
  • Page 322 st re-issue WSM.124 Section N (Elec. Equip.) Page8 Commutator A commutator in good condition will be smooth and free from pits or burned spots. teUP INCORRECT CORRECT Fl1, 4. to generator Assembling end bracket and brushes brushes are badly worn, new brushes must be fitted and bedded to the commutator.

  • Page 323: Coil (Refer To Distributor)

    I st re-issue WSM.124 Section N (Elec. Equip.) Page 9 Armature 5. Unscrew the two pole shoe retaining screws by means of a wheel-operated screwdriver Indication of an open-circuited armature winding (See Fig. 7). will be given by burnt commutator segments. If Draw the pole shoes and coils out of the yoke armature testing facilities are not available, an and lift off the coils.
  • Page 324 I st �re-issue WSM.124 Page 10 Section N (Elec. Equip.) To replace the bearing bush in the commutator-end 2. Press the bearing (13) out of the end bracket bracket, proceed as follows:- and remove the corrugated washer (14), and felt ring (8). 1.
  • Page 325 st re-issue WSM.124 Section N (Elec. Equip.) Page 11 CONTROL BOX Equipment and General generator when the battery was in a low state of charge, particularly if the lamps were simultaneously We have tested and recommend the Avo Model 12 in use.

  • Page 326: Servicing

    WSM.124 st re-issu� Section N (Elec. Equip.) Page 12 REGULATOR VOLTAGE CUT-OUT all climatic conditions. In cold weather the volta'ge ADJUSTING SCREW ADJUSTING SCREW required to charge the battery increases, whilst in warm weather the voltage of the battery is lower. The method of compensation takes the form of a bi­...
  • Page 327 WSM.124 st re-issue Section N (Elec. Equip.) Page 13 Remake the original connections. be checked without removing the cover from the control box. A generator run at high speed on open circuit will Withdraw the cables from control box terminals build up a high voltage.
  • Page 328 I st re-issue WSM. 124 Section N (Elec. Equip.) Page 14 "FOLLOW THROUGH" STOP Unscrew the cut-out adjusting screw until It Is well O·OIO in.-CH>lO in. clear of the armature tension spring. Slacken the two armature securing screws. 0·025 in.-0·040 in. Press the armature squarely down against the copper-sprayed core...
  • Page 329 ROOTES MANUAL WSM. 124 Section N (Elec. Equipment) Page 14A Fig. 13. Fuse unit CONTROL BOX MODEL R.B. 340 GENERAL Check the generator by substitution or by disconnecting the generator cables and linking Equipment the larger generator terminal "D" to the smaller terminal "F"...
  • Page 330 ROOTES MAN UAL WSM. 124 Page 14B Section N (Elec. Equipment) VOLTAG E REGULATOR Using the correct tool, turn the voltage ad­ justment cam until the <:orrect setting Is Open Circuit Settings obtained-turning the tool clockwise to raise Ambient Temperature Voltage Setting the setting or anti-clockwise to lower It.
  • Page 332 sc re-issue ROOTES MAN UAL WSM. 124 Page 14D Section N (Elec. Equipment) 7. Repeat the above checking procedure until the 5. Adjust by carefully bending the fixed contact correct setting Is obtained. bracket. Closing the contact gap will raise the drop-off voltage.

  • Page 333: Servicing

    WSM, 124 re-Issue Section N (Elec. Equip.) Page 15 · STARTER MOTOR GENERAL shaft. If the commutator Is very dirty, moisten the cloth with petrol. The starter motor is a four-pole, four-brush machine having an extended shaft to carry the engine SERVICING engagement gear or starter drive.
  • Page 334 re-Issue WSM.124 Page 16 Section N (Elec. Equip.) wiring giving rise to a high resistance in the springs and move the brush by pulling gently on motor circuit. Check as described above. its flexible connector. If the movement is sluggish, remove the brush from its holder and -4.
  • Page 335 WSM.124 re-issue Section N (Elec. Equip.) Page 17 Remove the two through bolts from the commutator-end bracket, and take off the commutator-end bracket from the yoke. Remove the drive-end bracket complete with armature and drive from the starter motor yoke. If it is necessary to remove the armature from the drive-end bracket it can be done by means of a hand press after the drive has been dismantled.
  • Page 336 WSM.124 re-issue Page 18 Section N (Elec. Equip.) Insert the pole expander, open It to the fullest extent and tighten the screws. Finally tighten the screws by means of the wheel­ operated screwdriver. Replace the Insulation piece between the field i•...
  • Page 337 WSM.124 I st re-Issue Section N (Elec. Equip.) Page 19 STARTER DRIVE GENERAL the screwed sleeve; if there Is any dirt or other foreign matter on the sleeve It must be washed off The pinion and barrel assembly Is mounted on a with paraffin.
  • Page 338 WSM. 124 st re-issue Section N (Elec. Equip.) Page 20 DISTRIBUTOR GENERAL Special ignition for cold climate countries. The coil ignition equipment comprises a high The ignition coil is a 7-volt unit, and during normal tension induction coil and a combined distributor, running the excess voltage Is dropped across a contact breaker and automatic timing control ballast resistor In series with the coil primary...
  • Page 339 WSM.124 2nd re-issue Section N (Elec. Equip.) Page 21 Examine the contact breaker. The contacts must be quite free from grease or oil. If they are burned or blackened, clean them with very fine carborun­ dum stone or emery cloth, then wipe with a petrol­ moistened cloth.
  • Page 340 WSM.124 re-issue Section N (Elec. Equip.) Page 22 Indicates a broken or loose connection In the low Battery to control box tension wiring or badly adjusted or dirty contacts. Connect the voltmeter between the control box terminal "A" and earth. No reading indicates a faulty lead or loose connection.
  • Page 341 WSM.124 2nd re-issue Page 23 Section N (Elec. Equip.) Contact breaker and condenser from the original cable) and bend back the strands. Finally screw the nut into its terminal (Fig. 20). Connect the voltmeter across the contact points. If no reading is obtained, re-check with the con­ To make the connections to the terminals in the denser removed.
  • Page 342 WSM.124 2nd re-issue Section N (Elec. Equip.) Page 24 The complete shaft assembly, with centrifugal timing control and cam foot can now be removed from the distributor body (see (2) below). L.T. TERMINAL Contact breaker To dismantle the assembly further, remove the nut, insulating piece and connections from the pillar on CONTAC T BREAKER...
  • Page 343 re-issue WSM.124 Section N (Elec. Equip.) Page 25 3. Reassemble the centrifugal timing control. 7. Slide the terminal block Into Its slot. See that the springs are not stretched or 8. Thread the low tension connector and capacitor damaged. Place the cam and cam foot assembly eyelets on to the insulating piece, and place over the shaft, engaging the projections on these on to the pillar which secures the end...
  • Page 344 WSM.124 re-issue Section N (Elec. Page 26 Equip.) DISTANCE BETWEEN CONCENTRATED CENTRES OF HEADLAMPS AREA OF LIGHT --�,------ ..,, _ _.,_.-,- -�- .:-: '------�--.;..., - -�/ _j ____ _ ;..HEIGHT OF CENTRES OF LAMPS FROM GROUND • 2285. (A) FRONT OF CAR TO BE SQUARE WITH SCREEN CAR TO BE LOADED AND STANDING ON LEVEL GROUND (C) RECOMMENDED DISTANCE FOR SETTING IS AT LEAST 25 FT.
  • Page 345 .fth ROOTES MANUAL WSM.124 re-issue Section N (Elec. Equip.) Page 27 Fig. 24A Headlamp Assembly (Later Models) KEY TO FIG. 25 Fig. 24 Models) Headlamp Assembly (Early FRONT RIM SEALING RING KEY TO FIG. 24 RETAINING RIM I. REFLECTOR SEALED BEAM LIGHT UNIT 1.
  • Page 346 ROOTES MANUAL WSM. 124 re-issue Page 28 Section N (Elec. Equipment) can then be withdrawn and detached from the Ensure that the front of the car Is parallel with slotted connector-plug. the aiming board which is to be positioned at a distance of 25 ft.
  • Page 347 ROOTES MANUAL WSM. 124 6th re-issue Section N (Elec. Equip.) Page 29 SIDE LAMPS AND FRONT FLASHER SIDE LAMPS AND FRONT FLASHER BU LBS Rapier IV models BULBS Alpine IV models (Refer to Fig. 27) (Refer to Fig. 29) To renew a defective bulb, remove the two screws and detach the white and amber lenses.
  • Page 348 re-issue ROOTES MAN UAL WSM. 124 Page 30 Section N (Elec. Equipment) STOP /TAIL AND FLASHER LAMPS securing screws from the rear of the unit. (Alpine & lenses may be removed after removal of the lamp unit by unscrewing the four cross-headed screws. Bulbs can be renewed after removal of the trim When reassembling,...
  • Page 349 ROOTES MAN UAL WSM. 124 6th re-issue Section N (Elec. Equipment) Page 31 DIRECTION INDICATOR SIGNALS AND HEADLAMP FLASHER Direction Indicators Operation of Flasher Unit (See Fig. 31) The correct operation of direction signals requires This unit depends for Its operation on an electro­ that the bright filament In the parking and tail magnet in conjunction with the linear expansion of lamp bulbs (depending on the position of the switch)
  • Page 350 re-issue ROOTES MANUAL WSH. 124 Page 32 Section N (Elec. Equip.) CAUTION therefore, gives the driver a clear Indication that the direction signals are working correctly. In countries where the headlamp flasher operates on the main beam, it Is Inadvisable to use the flasher It will be noted that in order to maintain the continuously when the headlamps are already desired rate of flashing (British Ministry of Transport...

  • Page 351: Horns

    R0OTES MANUAL WSM.124 re-issue Section N (Elec. Equipment) Page 33 HORNS Lucas LOCK NUT Windtone Horns (Fig. 32) Models ADJUSTING NUT WT 618 and 9H: The horns operate on the principle of a resonating air column vibrated by means of a diaphragm which is actuated electro-magnetically by a self­...
  • Page 352 5th re-Issue ROOTES MANUAL WSM. 124 Section N (Elec. Equipment) Pa1e 34 69090, 69127, 69128, 69131 and Adjustment 69132. Where twin horns are fitted disconnect one whilst Remove the cover securing screw, carrying out adjustment on the other, at the same take-off the domed cover and remove time ensuring that the current supply cable does the cover retaining strap.
  • Page 353 ROOTES MANUAL WSM. 124 re-issue Section N (Elec. Equipment) Page 35 should not normally be necessary. However, in current being drawn by the defective horn in which an instance where a single or both horns fall to case the adjusting screw Is to be rotated slowly operate satisfactorily the exact cause can be quickly clockwise until the volume of sound Is restored, diagnosed and rectified as follows:-...

  • Page 354: Maintenance

    re-issue ROOTES MAN UAL WSM. 124 Page 36 Section N (Elec. Equipment) WINDSCREEN WIPER GENERAL SERVICING Poor performance may be due to either mechanical The motor and gearbox are mounted on pillars or electrical faults, not necessarily connected with cast as part of the gearbox. The rotary motion of the motor Itself.
  • Page 355 ROOTES MANUAL WSM. 124 4th re-issue Page 37 Section N (Elec. Equipment) GROOVE IN GEARBOX COVER ALIGNING PIP Limit (parking) switch-to adjust (Refer to Figs. 34 and 35). DR3 wiper motor With the wiper arms positioned on their serrated spindles so as to provide the best arc of wipe, the blades should be parked at the lower edge of the screen.
  • Page 356 4th re-issue ROOTES MAN UAL WSM. 124 Page 38 Section N (Elec. Equipment) Alpine I Refit arm and check sweep of operation as described on Pages 37 and 38. To obtain the best operating sweep, the recom­ mended procedure is to fit the wiper arm to the serrated spindle so that, with the glass wet, the SPRING RETAINING CLIP full extent of the sweep away from the parked...
  • Page 357 ROOTES MANUAL WSM. 124 re-issue Section N (Elec. Equipment) Page 39 INSTRUMENTS AND CONTROLS Instruments-to remove and refit Take off contact plate and springs. Always disconnect the battery positive lead before carrying out any work behind the Instrument panel Remove three screws securing the hub mouldings to avoid the risk of short circuits.
  • Page 358 ROOTES MAN UAL WSM. 124 re-issue Page 40 Section N (Elec. Equipment) ELECTRIC IMPULSE TACHOMETER a D.C. voltmeter movement to which a pointer Is attached, so that when the engine Is running this {Refer to Fig. 37) moves round the instrument dial which is cali­ brated from 0-6,000 r.p.m.
  • Page 359 re-issue ROOTES MANUAL WSM. Section N (Elec. Equipment) Page 41 Fuel and temperature indicators FUEL GAUGE (Refer to Fig. 38) (Later Models) TANK UNIT The blmetal resistance equipment for fuel contents and temperature indication consists, in each case, of an indicator head and transmitter unit connected to a common voltage regulator.
  • Page 360 4th re-issue ROOTES MANUAL WSM.124 Page 4l Section N {Elec. Equipment) LOCATION AND REMEDY OF FAULTS STARTER MOTOR TROUBLE Remedy Symptoms Possible Causes engine, indicated Locate and remedy cause of stiffness. Stiff ability to turn by hand. If engine can be turned by hand then trouble may be due to:- Battery discharged.
  • Page 361 2nd re-issue ROOTES MANUAL WSM.124 Section N (Elec. Equipment) Page 43 VOLTAGE CONTROL-GENERATOR TROUBLE Symptoms Possible Causes Remedy Generator charging when running at about 20 m.p.h. with no lights in use. Due to:- Broken or loose connection Examine charging and field circuit wiring generator circuit, or regulator not Tighten loose or replace...
  • Page 362 re-issue ROOTES MANUAL WSM. 124 Page� Section N (Elec. Equipment) IGNITION TROUBLE Symptoms Possible Causes Remedy Battery discharged. Starter will Battery should be recharged by running not turn engine and lamps do not car for a long period during daytime. Alternatively, recharge from an indepen­...
  • Page 363 RO OTES MAN UAL WSM. 124 re-issue Section N (Elec. Equipment) Page 45 Symptoms Possible Causes Remedy Clean contacts with fine carborundum Dirty or pitted contacts stone or fine emery cloth and afterwards with a cloth moistened with petrol. Contact breaker out of adjust- Adjust gap to correct setting.
  • Page 364 ROOTES MAN UAL WSM. 124 4th re-issue Section Equipment) N (Elec. Page 46 RAPIER SERIES Ill and IIIA WIRING DIAGRAM COLCUlf .__ff 81.UE W"41T• .,..cw,, Yl't.LOW I'" " c;,tffN ltl:0 '"""""P&-a & &LA CK SNAP CONNECTOR LOCATIONS Top right-hand corner of boot . On right-hand front wing valance.
  • Page 365 :::, = u, ::D -· 0 0 -f -> J� 110P LIGfn lwtTCH DIST ... UToa ..J1..i,, r­ l4-.li...-<=>---..lii-.--l;""3il:-C:"<:--...!i!:..LH ITOPLAMP � ! ,ij' � $CAllNW1�£A MOTOR ANO. IWITCH O'IINMUYI. CIR.CUit (Wlllll """" � )> ! :! ' " 2! LH.
  • Page 367 I st re-issue ROOTES MANUAL WSM. 124 Page.49 Section N (Elec. Equipment) ALPINE SERIES Ill STANDARD AND G.T. MODELS WIRING DIAGRAM • OPTIONAL EXTAA§ SMQWN THUS :- ·--------- 70 14 LOCATIONS OF SNAP CONNECTORS A-Left-hand front wing valance F -At rear of facla adjacent to instruments B-Rlght-hand front wing valance G-At left-hand side of gearbox C-Beneath facia adjacent to steering column...
  • Page 368 ROOTES MANUAL WSM. 124 st re-issue Page 50 Section N (Elec. Equipment) SNAP CONNECTOR LOCATIONS Rapier Series IV (Early Models) A-At rear of right-hand tail lamp cluster B-At rear of left-hand tail lamp cluster C-Beneath left-hand side of facia D-Beneath right-hand side of facia E -At rear of left-hand quarter trim F -Beneath facia adjacent to steering column J -Upper left-hand corner of luggage compartment...

  • Page 369: Wiring Diagram

    RO OTES MAN UAL WSM. 124 3rd re-issue Section N (Elec. Equipment) Page 51 RAPIER SERIES IV (EARLY MODELS) WIRING DIAGRAM CO\..OUR CMAR1 e,1.ua. WMITE, SQOWN. "IEl_LOW GlltlrN, S10C1-AMP R.H. H!'AOL.AMP R.M. MOAN6. HEADLAMP I.. ,H. 5'0C.L.AMP L.M. M41NMAM WA,.NINO LICHT o,•...
  • Page 371 RO OTES MAN UAL WSM. 124 Page 53 Section N (Elec. Equipment) RAPIER SERIES IV (LATER MODELS) - WIRING DIAGRAM COLOU"' CHA._T 8LU., WMITllt, &ROWN. y� - . GREE .."e _ � - s � '· .:::. ' =. �...
  • Page 372 re-issue WSM.124 Section O (Body) Page I BODY CONTENTS Pa,es 1-27 UNDERFRAME DIMENSIONS Page -Alpine -Rapier SUPPLY OF REPLACEMENT BODY COMPONENTS WEATHERSTRIPS WINDSCREEN BACKLIGHT INTERIOR DOOR HANDLES· TRIM PADS WINDING WINDOWS QUARTER LIGHT GLASS NO-DRAUGHT VENTILATOR FRONT SEAT ... FRONT SEAT SQUAB REAR SEAT CUSHION REAR SEAT SQUAB ARM RESTS...
  • Page 373 WSM. 124 3rd re-issue Page 2 Section O (Body) Page EXTERIOR DOOR HANDLE STRIKER UNIT WINDOW REGULATORS BONNET BONNET LOCK BOOT LID BOOT LID LOCK GRILLE ASSEMBLY BUMPERS BODY MOULDINGS NAME BADGES...
  • Page 374 PRINCIPAL UNOERFRAME DIMENSIONS - ALPINE Series I & -· J: o · :, i:i 0 ..REA!l !'>PRINC. REAR SPRING STEERING UNIT I.OCATION FRONT EYE LOCATION REAR $HACKlE LOCATION FRONT SUSPEN:-,ION CR!»$ MCM&[R MOUNTING 5353 19 -22·34" ( 56• 7+3 1.-1•66"...

  • Page 375: Rapier

    RAPIER PRINCIPAL UNOERFRAME DIMENSIONS REAR SPRING REAII SPRING STEERING UNIT LOCATION FRONT EYE LOCATION "EAA SHACKLE LOCATION FllONT SUSPENSION Clt05S MIMUll MOUNTING lll!AII ENGINE MOUNTING " 387+ 1.-1•66• ( 4•216 C.M.) 7.-0·53" I • 350 c.M.) 13,--Z.·96" 7•.518 C.,IWI. ) 19 _2;t,34-•...

  • Page 376: Supply Of Replacement Body Components

    / st re-issue WSM.124 Section O (Body) Page 5 SUPPLY OF REPLACEMENT BODY Bonding COMPONENTS A period of 15 minutes should be allowed for the Body components are not supplied as service adhesive to become tacky before the rubbers are replacements In finished trim condition.
  • Page 377 st re-issue WSH. 124 Page6 Section 0 (Body) WINDSCREEN-To remove and refit Rapier The services of two operators are necessary to carry out the removal and refitting operaclons, one work­ ing from inside the car and one from the outside. The windscreen is located and retained in position by means of the glazing rubber around its periphery.
  • Page 378 WSM.124 1st re-issue Section O (Body) Page 7 Fig. 3. the chrome (Rapier) Method of fitting beading flange by pulling the ends of the cord. Pull out this Carefully remove any surplus sealing compound with a rag slightly dampened with petrol or white cord completely.
  • Page 379 WSH.12.C Page 8 Section O (Body) BACKLIGHT-To remove and refit Rapier The services of two operators are needed to carry out the removal and refitting operations, one work­ ing on the Inside and one on the outside of the car. The glass is located by means of the glazing rubber around its periphery only.
  • Page 380 WSM.124 re-issue Section O (Body) Page 9 BACKLIGHT-To remove and refit Alpine The backlight is located by means of the glazing­ rubber around its periphery only. No other fixing is used, but the contacting surfaces are treated with "Seelastik" during assembly. To remove Take off the two corner cover plates from the upper and lower chrome mouldings.

  • Page 381: Interior Door Handles

    WSM.124 Page 10 Section O (Body) When the pin locates with the hole in the spindle, force it home, and allow the escutcheon to return over the handle shank. Repeat the procedure with the window regulator handle, ensuring that both the windows are in the same positions before the positions of the regulator handles are matched.
  • Page 382 WSM.124 Section O (Body) Page II DOOR PULL-To remove All models These are retained by two self-tapping screws, the removal of which frees them from their locations on the door. TRIM PAD-To remove and refit All models Remove interior door handles. The trim pads are attached to the door panel by spring-In clips which are concealed.

  • Page 383: Quarter Light Glass

    WSM.124 Page 12 Section O (Body) QUARTER-LIGHT GLASS-To remove and refit Rapier (Fig. 15) Remove window winding handle. Remove rear seat cushion and squab. The retaining screws for the squab are accessible from inside the boot. Remove the trim panel from below the window aperture.

  • Page 384: Front Seat

    WSM.124 Section O (Body) Page 13 Slide the seat forwards and rearwards on its runners to gain access to the bolts. To refit Reverse the above instructions. FRONT SEAT-To remove Alpine Slide the seat backwards to expose the forward retaining screws, and forwards for the rear screws. Upon removal of these, the seat assembly is free to be removed from the car.
  • Page 385 WSM.124 Page 14 Section O (Body} Coupe) Fig. 16. Door glasses and mechanism (Rapier DRAIN CHANNEL WINDING WINDOW FRAME QUARTER LIGHT FRAME GLASS WINDING WINDOW GLASS GLAZING RUBBER I I, GLASS CHANNEL ANO CAMPLATE WEATHERSTRIP INNER FRAME SEAL SPECIAL NUT WEATHERSTRIP GLASS RUN CHANNEL 2-4.
  • Page 386 WSM.12'4 Page 15 Section O (Body) Fl1, Door rtasses and mechanism (Rapier Hardtop) QUARTERLIGHT FRAME INNER FRAME LIFTING GLASS GLASS CHANNEL AND CAMPLATE GLASS GLAZING RUBBER WEATHERSTRIP SEAL GLASS "'· GLASS RUN CHANNEL DRAIN CHANNEL RETAINER {DOOR TRIM PAD) SEAL WEATHERSTRIP MOUNTING BRACKET REMOTE CONTROL...
  • Page 387 WSM. 124 Section O (Body) Pase 16 To refit Enter the clips at the top edge of the squab and push the lower edge of the squab Into position. ARMREST-To remove Rapier From below the armrest remove the outer screws and take off the armrest.
  • Page 388 WSM.124 Section O (Body) Page 17 Release the draught welt from above the doors, door flanges and backlight aperture and allow it to and down as far as the striker. become nearly dry. Remove the rear quarter trim panels. To refit the lining, reverse the removal procedure. Remove backlight glass.

  • Page 389: Door Locks

    WSM.124 Page 18 Section O (Body) DOORS All models Lubrication It Is essential that the hinge pins and door locks are lubricated at regular Intervals. On Rapier cars an oil hole Is provided In the shut face of the door approximately on a line with the operating push-button of the exterior handle When not In use, the oil hole is sealed by a polythene grommet.
  • Page 390 WSM.124 Page 19 Section O (Body) From inside the door casing remove nut at front ,IJJ-' and screw at rear. Both are fitted with plain and shakeproof washers. To adjust On the reverse side of the push-button is a plunger held by a locknut.
  • Page 391 WSM.124 Page 20 Section O (Body) WINDOW REGULATOR-To remove All models Remove interior trim. Temporarily replace window winding handle and lower window to approximately halfway down and support the glass. Release the lower ends of the glass run channels. Remove the screws securing the regulator to the inner door panel.
  • Page 392 WSM. 124 re-issue Section O (Body) Page 21 BONNET-To remove Alpine (Fig. 27) Support the bonnet lid with a suitable sling In the open position. Remove the four setscrews with their washers from each hinge. (I) The bonnet lid is now free to be removed. To refit, reverse the above instructions.
  • Page 393 WSM.124 Page 11 Section O (Body) --===::W ' Fi1, 32. Components of the boot lid lock (Rapier) I. LOCKING BARREL 5. SPRING PUSH-BUTTON 6. PUSH-BUTTON ASSEMBLY HOUSING BRACKET LOCK Replace both striker unit and lock by reversing the above procedure. Adjustment of the striker Is carried out by screwing in or out of the striker pin, finally locking up with the locknut.
  • Page 394 WSM.124 st. re-issue Section O (Body) Page 23 Open the boot lid, and from the underside pull out FRONT GRILLE ASSEMBLY-To remove the number plate lamp wire from its snap con­ Rapier nector. Support the lid with a suitable sling and remove the Disconnect the battery.
  • Page 395 Friction bushes are used In the retention of the Itself. This bolt passes through the bumper back badge on the bonnet, t;he name "Sunbeam" on the bar. bonnet surround, and the "Alpine" plaque on the FRONT AND REAR BUMPERS-To remove rear end of the front wings.
  • Page 396 WSM.124 2nd re-issue Section P (Lubricants) Page I RECOMMENDED LUBRICANTS CONTENTS Page No • ... 1-3 LIST OF RECOMMENDED LUBRICANTS ...
  • Page 397 WSM, 124 re-issue Pagel Section P (Lubricants) RECOMENDED LUBRICANTS ENGINE Where prevailing climatic temperature ls:- Above 70 ° F. (21 ° Shell X-100 30 or Shell X-100 Multlgrade 20W/40. ° ° ° ° SUMP F. to 20 F. (27 to -7 Shell X-10020/20W or Shell X-100 Multlgrade I0W/30.
  • Page 398 WSM.124 re-Issue Section P (Lubricants) Pagel REAR AXLE ° ° *HYPOID minus I0 F. (minus 23 Shell Spirax 90 E.P. Above, ° ° minus 10 F. (minus 23 Shell Spirax 80 E.P. Below, SPIRAL ° ° F. (0 Shell Splrax 140 E.P. Above, °...
  • Page 399 WSM.124 Page 1 Section Q (Oil Seals & Bearings) OIL SEALS AND TAPER-ROLLER BEARINGS CONTENTS (3 Pac••) SEALS Page No -Leather seals impregnated with wax -Synthetic rubber seals TAPER BEARINGS ROLLER -Cups -Roller assemblies -Cones on stationary shafts -Cones on revolving shafts ...
  • Page 400 WSM.124 Page 2 Section Q (Oil Seals & Bearings) OIL SEALS Before fitting, carefully examine the seal and borne by the seal, resulting in damage or distortion to the latter. remove all traces of dirt or grit. This should be done by wiping carefully with a cloth moistened Before pressing the seal into the housing the with clean oil.
  • Page 401 WSM.124 re-issue Section Q (Oil Seals & Bearings) Page 3 TAPER-ROLLER BEARINGS The bearing assembly consists of two parts, the scrupulously cleaned out and the cages packed outer race or cup, and the roller assembly, I.e. between the rollers with new lubricant of the roller secured In a cage on the cone or inner race.

  • Page 402: Heating And Ventilation

    ROOTES MANUAL 124 2nd re-Issue Page 1 Section R (Heater) HEATING AND VENTILATION CONTENTS Page No. GENERAL DESCRIPTION Series Ill and IV Rapier I-IV Alpine Series •.. ADJUSTMENTS Ill and IV Rapier Series BLOWER To remove and refit-Rapier -Alpine CONTROLS To remove and refit-Rapier -Alpine HEATER...
  • Page 403 ROOTES MANUAL 124 re-issue Section R (Heater) Pa1e2 HEATING AND VENTILATION These instructions apply only to the Rapier Series Ill and IV heater. (Sunbeam Rapier Series Ill, IIIA, and Series IV-These kits not suitable Series II earlier vehicles. Serles The adjustments given below apply to Series Ill, I/IA and IV only.
  • Page 404 WSM.124 Section R (Heater) Page 3 Fi g . Ventilation The "Air Mixing Valve" (A, Fig. 1) controls the mixing of the hot and cold air. When this valve is in the horizontal position all the air by-passes the 4914 heater matrix through the "Cold Air Passages"...
  • Page 405 WSH.124 Section R (Heater) Page 4 DI­ Di­ • • ..Fie. 4. Increased heating to car and screen The "Air Outlet Valve" (B, Fig. 1) controls air flow Into the car Interior. It Is closed when the "Car" lever Is at "off"...
  • Page 406 WSM.124 re-Issue Section R (Heater) Page 5 (C) and cold air only is directed to the windscreen. Movement of the "Screen" lever to the "DE-ICE" (Fig. 2). position restricts the "Car" air outlet and so Increases the "SCREEN" air flow to maximum (See Further movement towards the "DEFROST"...
  • Page 407 WSM.124 / st re-issue Section R (Heater) Page6 2. "SCREEN" Control (See Fig. 7) Slacken screw (N), fully close the air outlet It Is also necessary to ensure that the air outlet valve by finger pressure on cam (Y) and re­ valve is In its correct position when the tighten screw (N).
  • Page 408 ROOTES MAN UAL 124 Section R (Heater) Page7 BLOWER-To remove and refit. Remove control lever knobs (screw off). Disconnect the battery. Remove console and filler panel (Series IV only). Release the branch pipe at the wing valance and Release the lower facia panel. remove air hose between branch pipe and blower.
  • Page 409 ROOTES MAN UAL 12-4 Page8 Section R (Heater) ALPINE (Ser/es I-IV) GENERAL DESCRIPTION Release the control cable. The heater element and its associated control,· Disconnect each hose at the water valve. supplement the fresh air system built into the car. Undo the retaining screws and remove the water The temperature of the fresh air, directed to either valve complete with bracket.
  • Page 410 ROOTES MAN UAL 12'4 Page 9 Section R (Heater) BLOWER-To remove and refit. Retitti ng is a reversal of the above operations. Disconnect the battery. When refitting the blower ensure that the upper sponge collar is in position and also that the blower Disconnect the blower:- outlet enters the rubber at the air box inlet.

  • Page 411: Special Tools

    WSM.124 2nd re-Issue Section S (Special Tools) Page I SPECIAL TOOLS Obtainable from: & V. L. CHURCHILL CO. LTD. Great South West Road Bedfont Feltham Middlesex, England Engine RG.I0A-7 ..Adaptor Set. Use with RG. I0A Valve Guide Remover/Replacer. RG.32-2 Adaptor Set.
  • Page 412 re-ls�ue WSM.11-4 Pagel Section S (Special Tools) RG.188A-2 Rear hub thrust block and bolts (centre lock hubs). RG.292 Differential bearing replacer. Use with 550 handle. RG.1105-1 Bevel pinion bearing outer race remover/replacer. Used with RG.1105. RG.295A ..Differential assembly jig. RG.4221 B-20 Differential bearing remover adaptor.
  • Page 413 _.,,. PRINTED IN ENGLAND WREN PRINTING CQ. LTD. LONDON.

This manual is also suitable for:

Alpine i series: apline ii seriesRapier iv seriesAlpine iii seriesAlpine iv series

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