91 Slices
Medium 9781855209510

Chapter 18 - Preparation for the Big Day

Gordon Lund Brooklands Books ePub

Setting up

Fill the petrol tank and then raise the car to sit on railway sleepers on its wheels. Work the suspension to level out the ride height. Weight the car as recommended in the workshop manual or ask some nimble people of similar weight to sit in the car. With the torque wrench set at the correct readings, tighten up all the suspension nuts and bolts that were left loose previously. Return the car to the ground and check the ride height with the heights quoted in the workshop manual.

Before you do anything else, check all around the car for the obvious things you may have missed. Double check that all hoses are tight and that there are no petrol leaks. Connect up the battery and remove the spark plugs from the engine. Turn the engine by hand with a spanner on the engine pulley bolt, ensuring that all is free. Remove the spanner. spark plugs from the engine. Turn the engine by hand with a spanner on the engine pulley bolt, ensuring that all is free. Remove the spanner.

Under the bonnet. All finished and ready to fire up

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Chapter 9: Cooling and Heating

Greg Hudock Brooklands Books ePub
Medium 9781855209657

Chapter 6 Front Suspension

Greg Hudock Brooklands Books ePub

The front suspension consists of an upper and a lower wishbone, torsion bars and a stabiliser bar. Hydraulic shock absorbers are used to dampen the movement of the front suspension. All parts of the front suspension can be removed individually.

The front suspension assembly is fitted as a complete unit to a strong sub-frame. In the case of larger repair work, it is possible to remove the complete sub-frame which can then be dismantled. The removal of the sub-frame is only described briefly near the end of this section, as it will be rarely necessary.

Fig. 6.1. – The attachment of the front shock absorber. Note that the collar of washer (2) must face downwards.

Fig. 6.1 shows the attachment of a shock absorber at the upper and lower ends. A single nut secures the shock absorber at the lower end, whereas a special mounting bracket is used at the upper end. Remove a shock absorber as follows:

Faulty shock absorbers make a rumbling noise, even when the vehicle is driven over a fairly level road. If this is the case, there is no need to check the shock absorber. Replace it immediately.

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Chapter 9 Brakes

Greg Hudock Brooklands Books ePub

Disc brakes are fitted to the front wheels of all models, but different brake calipers are used in vehicles covered in this manual. In the vehicle data plate you will find a code, commencing with “1L”', with an additional letter behind. The code refer to the fitted disc brakes and can be interpreted as follows:

Ventilated brake discs are used, but there are different brake disc thicknesses and diameters, depending on the fitted engine. For convenience, all brake systems are covered, irrespective if they are fitted to diesel models or not.

The rear wheels have disc brakes. A dual-line brake circuit is employed. A brake servo unit is standard fitting. A separate vacuum pump is used to feed the vacuum system for the brake servo unit. There is a brake pressure regulator fitted to some models only. Most models are fitted with an ABS system, which for reasons of road safety should not be tampered with.

The master cylinder cannot be repaired or overhauled and must be replaced as a complete unit if faulty.

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Chapter 4 Drive Shafts

Greg Hudock Brooklands Books ePub

The drive shafts are the same on both sides. The front suspension is fitted with torsion bars. These bars are under tension and the upper wishbone is pushed down by the tension of these bars. If you are familiar with earlier T4 models, you may know that special support struts were required to release the tension of the torsion bar. This is no longer required on models covered in this manual. A few additional operations are required to remove the drive shafts, if an automatic transmission is fitted.

Note: The wheel bearings must not be placed under load when the drive shaft is removed, i.e. never lower the vehicle back onto its wheels after you have removed a drive shaft. From model year 2001 new wheel bolts are fitted. Section “Front Suspension” gives details.

Proceed as follows to remove a drive shaft from a model with manual transmission, but note that some of the operations are only referred to, but not described in detail. Detailed descriptions of these operations can be found in the “Front Suspension” section.

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