CG, 7 T30Q Junior Se technical characteristics and principal inspection specificationsAeenennaemeune TECHNICAL CHARACTERISTICS *ttsseeeseeeuw Principal characteristic data ...... Page 3 i | ieee ogee ee te ere eg Prescribed oils and lubricant eee tee M8 Garburétion 2 eee ee eee tee eee eee oo. Idling adjustment 6. eee eee ee eee see MOS Float level adjustment 6. eee eee eee see" 6 Valve timing 6 eee eee eee eee oT Electrical equipment see eee reece ee tee "8B mp) Googeg00G dou G00dD oo eo) ‘Tightening torque specifications .. eee eee eee eee ee OM OO wees “MAJOR INSPECTION SPECIFICATIONS ‘eewnwee Camshafta 2. eee eee Valves and valve guides . « Valve seats»... + eee Valve cups... ee eee Valve springs». +--+ Connecting rods... ++ y Piston pins... 2. + Piston pin holes. « Pistons and piston rings cylinder barrels 2... Crankshaft .. +--+ Clutch ee eee eee (Geurtoce ee ese Rear axle and suspension ~ Front suspension... Brakes ee eee eee Wheel alignment Checking of wheel angles and car trim under static lod 2... 6s Page 18eee swenes TECHNICAL CHARACTERISTICS steteeeetenees Principal characteristic date Wonber of cylinders oe ee ee ‘ eee eee eae CaCeeCaCOce am accecd Hh ow (2.913) Stroke eee ee Bam (2,053) al cylinder capacity oe ee ee 1290 ee power at 000 FR ee ee Sag 103 CY Front track oe ee ee TON (HT) Rear teak oe ee ee Te an (2A) Weelbe e e e e Bb en (78H) Min, turning clrele co ee ee ee ee e000 ae (54) Overall Teogth ee ee ee eo oo MRD an (1384 5/8") Overalt width ee ee eo 1580 am (512 1/48) Overall hetght (unladen) ee ee NS am (408) Dry weight, with tools and Jack 6 ee ee ee ee ee ee 80g (2020 To8) Weeder of sets ee eee ‘ Fuel consuaption for 100 ta (CUMA standard) 6. ee ee ee ee i (28.8 99.68) For best engine perforaance, the use of prontue-grade fuel te advised, laos} Teeetag ie (uur ip te 1 te] 1000 To oD Ka Mfr remion In (200 01.) | (200 to 1000 at.) tam | ooh | tam | ooh tam | om | ast of wf sl a «| 2 and ws] 0] 2] @ nw] 8 rd ni] s] a] ss 1 | os With tO finad delve Se | al eels |e a Ball sth me] om | wa] lowe tm | 105 fev, -[- =| - w| 2 In,presaure at idling speeds 5-1 tg/ea2(7=14 pst) In, pressure at top speed: 3.5 fo/cu2 (50 pst) sx.pressure at top speed: 4.5-5 Kg/ca2(B5-70 pst) Warning: Check that generator warning light goes off as soon the engine excends 1,100 roa.TIRES Inflation pressures (cold tires) Front wheel Kylead___ost 6 PIRELLI 155 x 15 Cinturato S oes eee eee eee eee ELLA 155 « 15 Cinturato S i i aT at MIGHELIN 155 x 15x, a * Inflate to the lover pressure e+ inflate to the higher pressure for use vith full Toad and top speed (highvays) Refillings about about 7.65 gale 10,1. gals 7.98 gal Water (engine & radlator) 6. 5 124 gale fuel (reserve TW/1.5 gale 62 /1.8 gals US) . « to nex, level # about vas ats | 5.05 ate tare ome (at at a | ue Oe | Gaarbor eee about 32 pts | 28 ots Differential... « + about 2s ots | 20 ots | bout Sot 8 ot Steoring box. al anount af of7 In the clreult (sump, filter,pase (*) Mis quantity 12 that needed for raqular changing: the sages) 18 5,75 Nos. (5.7 ats 6.8.) (6.8 ats U.S.). Presoribed oils and lubricants Wl SAE = MGT Recossended commercial equivalent aber agie SWELL SME 20W/0 | F.1 Supersotorott Engine (*) faiths tutesgrade 20 api [000 Mt torade 20/80 box SAE 90 FA Rotra SAE 90 Dontax 90 | (for correct use of lubricant refer to foatoate SAE 90 EP |etRatra Hypotd SAE 90) Spirax 90 EP Steering box and differential SAE 60 & |Fotra Hypotd SAE 9] Soiree ser | Propeller shaft universal Joints and sliding yoke watt Ft Grease 15 Retinax 6 Front wheel bearings Ml 2/3 I F.1 Grease 33 FD | ‘Brake fluid = Castrol Girling Brake Fluid Aeber L ‘ AGIP F.1 Superaotoral) Multigrade 10 W/' (A) For ste eratures below O° ¢ (32°F) ve advise the use o "|For steady teaperats OF © (32°F) ve advise the (Se ea 02 a5 directed on Mate 1 = AGIP-FA1 Rotra Hypold or SHELL Spirax should be used exclus rad transfor aopled on them SAE = Society of Autonot ive Enginears APL - mmeriean Petroleua Institute NLSt - ational Lubeicat ing Grease Institute In counteies shere the recossended lubricants are not avallable it is possibile to replace thes vith products of other leading Coapanies provided that In accordance vith the prescribed specifications.GCarburetion 2 Corhurettore WEBER 40 DGOE 28 Nester ete es checl . waa (138) Hain Jot. eee : Ww Hato air aatering Jet... 6. rr) Idling Jot eve cece eee sort dling alr aetering Jet... 2 Choke fet ee eee eee eee eee 6m Acceleration puap Jet... « §od0n00 S Travel of sccaloration puap control rod. . eee eG Wa (.554) Delivery of acceleration puap every 20 strokes (for each barrel)... « Site, Needia valve seat dia... . go 1.50 a0 (.08") Float weight. « peneeee co 28 ore Distence of fusl Vevel fron Float chanbor flange (vith a pressure of 2 ate (OYO") HzO upetraaa the needle valve) « see ME Soa (12 to 1.18) dling 04 justment F Adjusting screw for atotaua ‘opening of thratte M Idlteg atzture adjust ng screw, S Serev for synchronizing throttles of the tye carbue rettors, T Joint for contrel Nnkage (to pedal). REPARATORY STEPS = Check the ignition ttaing and Inspect the electric syston (spark plugs, distributor, cot, ete.) for proper operat ion, = Renove the alr filter elonont and clean tt thoroughly. «= Check the flexible aounts Setveen carburstters and Intake aantfold for tightness, ALIGHING THE THROTILE VALVES = Detach the control linkage *T* fro carburettors. = Slacken the scrovs *F¥ and ‘S* alaost fully. = Operate the throttles a fow tines to ake sure there is no binding. = Fully depress the trottle control lever of rear carburettor so that the throttles are fully closed; then screw in the sereu "S! until contact ts ade, touing = Back up the serou "HY of half a turn, = Tighten the screw "F¥ to contact, then screw tt In one sore turn to ensure feeding of engine. = Connect the accelerator control linkage *T* to carburettors. «= Start the engine and ware It up. = If necassary, back up the ser "F* very slowly until the engine runs at about 600 to 700 rpes.Float level ytmen’ VEBER 40 DCDE 28 carburettor Hake sure the float vaight 18 as specified (28 rs - .9 oz), that there are no Teaks or indentations and that float can rotate freely about the pivet pln, = The float veight aust net be altered; con float operation, = Check that needle valve (1) 1 well sereved Into Ute seating and that the spring-loaded ball (5) part of the needle (2) 1s not janned. joquently haphazard repairs (tinting, ote.) are detriaental to proper = Hold the carburettor cover tn a vertical position as shown in the figure so that the float (6) does not depress the ball, = With the cover vertical and the float tongue (4) {n Tight contact with the ball, the two floats should be at fa distance Ae8,5 an (.33") fron the cover sating surface uith the gasket fitted and vell stuck te the cover, = non the Vevel har been sat, check that the travel (8) of the fl posttion of float pivat tal? (3). 1s 6.5 an (.26*); If necessary, adjust the = The adjustaent described above vi1t correapond to a fuel level of 20 £.5 ae (1.12 to 1.16") fron the upper face of the float chasber (vith a prassure of 2 ats = SOF HO upatrane the needie valve). = If distance (A) Is nat as specified, slightly band the float tongue (4) unt? the correct distance is obtained: Iaspeet the vorking surface of the float tongue for any sign of aickn’ bch aay restrict the free aovenent of naedte (2). = Than FUL the carburettor cover and check that the float can sove freely without ‘rubbing apatact the walls of the float chasbor, CAUTION The float level should be checked whenever the float or the needle valve has been changed, In the Tatler case it 1s also advisable to replace the gasket and sake cartain the nev valve is securaly sereved Into Its seating,Valve timing Ghecking of valve opening and clos! les Clearance (vith cold engine) batveen the unlobed profile of cams and the valve cup cell tng: We vee eee eee e eee cece eee ee 475 t0 500 on (0187 to 0187") chest. a ae cece eee eae S25 to 550 an (0206 to 0216) Goaniog of Intake valve Vt of ew oe eee ee ee ee 20 an (.008") corresponding te an angle fee ee ae before TOE of sem. 0" Closing af Intake valve: - Wt of co eee oe Soooganoues 20 an (.008") corresponding to an angle Opening of exhaust valve: Vift of cup. correspanding to an angle Closing of exhaust valve: see after BOof sem tem 15 on (0008) se ee + before 806 of seem lift of poe oe oe 215 an (.008") corresponding to an angle... + + + vee ee after TOC of 19°30" 5 190 le values of the actual di: of valve timing system with cold engine (clockwise rotation direction of the crankshaft seen from the front side): opening of Intake valve (before TC)... wee ams. closing of intake valve (after @0C). 6.6... ee sae SOF opening of exhaust valve (before BOC) «1... es 48 10" closing of exhaust valve (after TOC) . sees + me 10" Induction stroke eee ety ehaust stroke Sees ea: Ignition Firing order: 1-3-4 = 2 (no, 1 cylinder ts that at the fan side) Values of advance of ignition distributor Opening of contact points of ignition distributer . ee The distributor fe correctly fitted when the otter Is tovard the engine, 20 to 40 we (,014 to .0164) Maxtoun Advance Before TDC Pe TDC, F «Fixed advance We Raxtaun advanceVoltage eee eee as Battery ee eee ee eee ee Generator. eee ee ae Voltage regulator Starting aot colt Ignition distributor... Windshield viper. jadlights (high and low beses) Tall Nights « parking § stop. Front Vights ~ direction ladteators Tall Tights direction indicators Back-up Tight Front parking Tights conse plate Light Engine compartaent Tight Courtesy Tight Inside the car Side lights - direction Indicators Instrusent panel light... 5 + Tellatale for fuel reserve... Tell-tale for high boas. Telltale for parking lights... Tell-tale for direction indtcators Tellstale for generator... «5 Telltale for blower so... +s Ry om vee | GR) HVA eo WMA vee | BUR VO7 PS eo mA 000 ee aa WS 131 Tt . 45/50 asyauctric Eee sia ro a od 5 globular 5 cylindrical 3 tabularTightening tor ecification ENGINE. SEARGOK UNIT Ton, [ Wes ft |_Fanner of tighten after repairing, when cold... . [Uz to 6.0 | W.8 to 06.1| tk andretifteatthout ibe Ute of etn at erage ces cr css] 0 82 | a teat tea latte Soark GE eee eee 2:5 to 3.5 | 10.1 to 25.2] 0h grahtte reatesvhan cold Nuts of the canshaft e295 ee ee ae i]2 to 2.25 | 16.5 to 18.3 ta etl ute of the conecting rod cans 56 s] sto 5.3 | 36.2 to 38.3 soe ute of aain bearing caps. . gp06 sfartes | 37.9 t0 36. hoe Screws of flyvheel on crankshaft... ss. to faz to 45 | ao te 25 oo fut of generator pulley... 6060 se] 3t03s | 2.7 te 25.3 ary fut of gearbor aatn shaft yoke... an 6.8 , fut of gearbox layshaft oe ee eee eee als 38.1 ' Wat of gearbox halfcasiog oo eee eee e eee eee] MB 0 ' Bolts Joing gearbox outout shaft yoke to prop. shaft yoke . [4.5 to 5.5 | 32.6 to 3.7 ' Aut of gearbox Imer svivel ss. seen e ee as [3 to 265 | 22.6 to 26,4 ' REAR FRAME Screws securing ring gear to differential case... ...[4StoS | 22.6 to 36.1 ary Ringnut securing yoke on floal drive platen shaft .....] Sto [58 to 101.2 ‘ ats securing bearing housiog to real axle.tubes. ... . . [4.8 to 5.5 | 34.8 to 29.7 ' fats securing radius reds to body oe -|t0 to 11.5 | 72.4 to 83 ' futs securing radius rode to rear axle tubes. i [ts to 13 | 63 to ' ut securing reaction triangle to body... [AB to 5.5 | 24,8 to 30.7 ' ‘at securing reaction triangle to rear axle... .. «| 11 to 15. | 79,6 te 10.5] ' Screws securing rear brake caliper te support (ATE brakes), |2.3 to 2.8 | 16.7 to 20.2 ' Mate securing WOWOTS ee eee eee ee cee nL StO8 | ALA to 87K ' Glts Joining differential yoke to prop. shaft yoke... ./2.5to 4 | 25.2 to 28.9 ' PROUT FRAME Tut securing steering wheel to column os. ess 5 to 55 | 36.1 to 30.7 ary Serevs securing Buraan steering box cover vv... 5 + « [2.2 te 25 | 16,7 to 18 ' Serevs securing steering box & balTerank bracket to body . [4.8 te 5.5 ' Wuts of steering Tinkage ball Joints... 4.8 to 5.5 | 4.8 to 30.7 ' Wut securing stenring ara to BOK. eee ee ee 12.5 to 14 | 90.5 totot.2 ' Screws sveuring upper attachaont of shock absorber to bod 16.7 to 20.2 ' hut securing shock absorber to suspension ara... 5 « Sh.3 to O14) : Screws securing upper wishbone front ara to body. 16.7 te 20.2 ' fut securing upper wishbone front ars to rear ara 38 to 3.7 ' fut securing upper wishbone rear ara to body... 115 to 12 | 83 too ' fats securing lover wishbone shaft to eressoaoaber ... «| 12t0 18 | 94 to 120 ' Auts securing steering ara to steering knuckle... =. [4.8 to 5.5 | 34,8 to 28.7 ' fut securing upper vishbone rear ara to steering kruckle [7.5 to 8.5 | 54.3 to Ot. ' ut securing lover ball joint te wishbone oo... .. «735 to8.5 | 54.3 to O14 ' fut securing lover bell Joint to stearing knuckle... . . [7.5 to 8,5 | 54.2 to O14 ' tuts securing caliper support to steering knuckle... . . [A8 to 5.5 | 24.8 to 22.7 ' Screws securing front brake caliper to support (ATE brakes) |7.5 to 8.5 | 54.2 to 61.8 : Sereve securing front brake 41808. ee ee ee 15 to 8.5 | 54.3 to ots : tts securing Meels eee eee tos [Ane to 578 ' ATE geanes Front brake Bleed gered ove eee ee eee eee | Dito | 1,5 t0.25 dey Caliper Jotning bolts... vee es [2d to 34 | 21 to 26 ' lotet fitting to caliper (vithout gasket)... 2.2... Btott | Stee 'yee ATOR THSPECTION sai PERICHTEPSTICNS Diameter of journals: £ Diaaeler of Journal bearings: 3. fadial eloarancebetvean Journals and bearings 3ct TIONS a CARSHASTS: cece e 18,959 to 28.900 as {1.0618 to 1.0022") bene to 27,033 an (1.0620 to 1.0542) sees ta 078 an ( 0008 to 0028") or te tz ae ( 0026 te .coTt*) od play af canshaft in thrust bearing: Co... VALVES AND VALVE GUIDES Chast oes (sodtua type) a uv poonet [27.000 to 37.150 an |34.000 to 24,150] da, 0 (1.4857 to t.sszst) |(1.308 to 1.2828) t g stn | 0.072 to 8,967 ue | 0,835 to 8,980 m BYdie. m | (.asre to ast) | (-25te to 27) Totat | 109 to 109.3 an | 108.6 t0 108.9 a 2 Tenth 4.2512 to 4.213%) |(4.2758 to 4.2876) ‘utside dlanster vith guide reanved va wie {ite th i Projection of Intake valve guides from their recesses in cylinder nead 14,033 to 14,064 an ( 5528 to 3520") In cylinder hea D 9,000 to 9.015 on ( 13,600 te 14.000 aa ( Sas") st") 3544 to oH te Projection of exhaust valve guides froe their recosses 'n the cylinder head 16.800 to 17.000 aa ( .662 te .689" } valve stem byoodeugad Clearance between guide asseabled in cylinder head and Intake bo oohaust Valve Diaaeter of valve guide seat in cylinder head. . Interference betveen seat and valve guide. . Outside diaseter of the valve seat... 2 6H Dianeter of recess in the ctinéer head for valve seat... 013 to 040 to 043 a (I 280 aw (0086 te 0031") 0031") 0005 to seate eee 13,900 to 14,018 un ( 5508 to .5518") DIL D Dee lots to 084 an ( 0008 to .0021") Tntake Exhaust BEGET to 2852 me | BAZ to 15.57 oe (1.5196 to 1.5209") | (1.256 to 1.260") 28,807 to 28.992 an | 35.722 to 35.757 ones (1.5314 to 1.532) | (s.9i56 to 1.4077") 28,522 to 38.557 we Boat (1.5169 to 1.5179") 2 te 18.857 a 0 35.882 a8 aversized 38,822 to 08.257 ae | 15.087 to 35.682 Interference between valve seat and recess in cylinder head... jCt.seee to 1.5200 (1.9038 to 1.4088") 100 to 040 an { .0028 to 016" -10-Ueive cups Ree {renee + A972 to 1.088 50.(1,3769 to 6.2775") * oversized . 25.173 to 15.185 an (1.2048 to 1.3854") Diasetar of cup seat In cylinder (ee 35,000 te 35,025 2a (1.3780 to 1.2789") head. 5 oversized , 38,200 to 15.725 ne (1.2250 to 1.2868") Clearance betveen seat and cup... .. «Sh O11 to 052 aa ( 0005 to 0020") fm ote fetta ety Taogthande tent Toa] Te ed] 22.2 te 23.1 Ka. 48.9 to $1.1 The sata k, fie wig tedta te Connecting rode Length between ¢ of big end and & of suall end of connecting rod. D 147.955 to 148,045 wa (5.8250 to 5.8205") Inside diaseter of the big end of connecting rod . wee eee E 53,685 to $3,708 an (2.1160 to 2.1164") Ingide diaaeter of bushing In the sual] and of rod... + « « 22.005 to 72.015 on ( 8068 to 8687") : standard |. 1.822 to 1.820 an ( 0718 to 0720") Thickness of connecting rod bearings... 4... F ‘Ist oversize 1.988 to 1.956 an ( .0788 to .0770*) ded oversize 2.078 to 2.083 an ( 0617 to. .0820*) fadtal clearance betveen crankpins and bearing for big and of connecting rod eee ee ee eee e eee 025 to .064.an ( .0010 to .0024*) Nextave out of parallelisn between. & of big end hole and of saalt ‘and hole measured on piston ener spring . 1 0217 an (,0018") 19,907 an (78777 to 78788") OD OF PID eee c eee c eee eeeeee el { Reese 2000 on (70708 to 72800") Bleck color 008 to 071 wa ( .0002 to .0008") Clearance betveun piston pin and saall ond hole - + 4 nite color ‘os te ote ea ( .0002 to 0007") Piston pin holes [Bleck coter [white evior__| 000 to 20.002 ea | 20.003 to 20.005 an} (20% to .7e748") | (.78752 to 7876") 19,006 to 19,909 an | 19,999 to 20.002 aa} (78786 to .78796") | (78796 to .70808") 20,000 to 20,0025 sa | 20.0025 to 20.0050 aa] (78000 to .78809") | (.78809 to .7e819*) Borge piston. eee eee eee eee Hable piston . 4 4 ad slay of the canaciog roe 3 the crankpins @ .200 to .300 ae (.0079 to .0118") cy"istons and piston rings Dianeter of pistons to be a 472) fron the Touer border of skict, For cylinder barrel classification pursase, use the sinisus dlaneter recorded, sured to square with the hole for piston pin and at a distance of L + 1012 (am. Clase A - BLUE Class 8 - Pre Class ¢ = GREEN 73,930 to 75.940 (2.9128 ta 2.91324) 73,925 to 73.935 ea! cerns Ve2,9126 ta 2.91308) 73.825 to 73.935 a (2.9128 to 2,9120¢) Borgo piston fable piston oe eee es KS. piston... Height of grooves 73,940 to 73.950 a8 (2,9122 to 2.9136) 73,935 to 72.945 aa (2.9130 to 2.913) 73,935 to 73.945 an (2.9130 to 2.9134") Jn piston for rings 72,950 to 73.960 (2.9136 to 2,910") 73,045 to 72.955 ae (2.91% to 2.9138") 73,045 to 72.955 aa (2.91% to 2.9138") “ iy aren oe ae ait central ag? petit ) T-1t | sowso [2.00 to 2.047 wm (0787 to one) 6.005 to 4.001 on (157 to 158") = 4 NAHLE | 2,025 to 2.040 aa (.0798 to .0803*)]4.015 to 4.030 an (.1582 to .1587*) F K. S. [2.022 to 2,067 am (0797 to ,0808")]4.008 to 4.031 an (.1578 to ,1582") a R = Iiieinese [ Somtesslen (chronlncplated) 1,878 to 1,890 aa (0718 to ,07EK*) Se Meiooss 1 caapression (onreal] «8 1,978 to 1.90 ae (078 te 078") v oF rings | ait control T 3,958 te 7,970 a» (1959 to 1564") vf eels ap af rings to be checked in ring gauge or in cylinder barrels... .. U 25 to 40 an ( 010 to .015#) ARLE | .035- to 062 an (0014 to .0024%)| .065 to .072 wn (.00'8 to .0028")| {nd play of rings in grooves | B0RGD | .032 to 060 we (,0012 to .0027*) | 038 to .073 ae (.0014 to .c02e")} Ks, | 03 to (.o0t3 to ,0027*) | .036 to .072 a (.0014 to .002e")} CYLINDER BARRELS Ly Cylinder barrel diaseter O11 control logs ‘BLUE PINK GREEN 73.985 to 73.998 en! 2.9180 to 2.9153") 73,095 to 76.004 a (2.2186 to 2.9187") 74,005 to 74,018 (2.5158 to 2.9161") NY Clearance between cylinder barrel and piston ‘IER Borge piston ith Wanle piston 045 to .060 fear Vast Jactton of barrels fram cylinder block face roughness. (.o0te te .0025") 050 to. .089 a 4000 to .0sa n- with 15. pistar (0020 to 0027 120 a (,0067") 010 a {,0008") 050 en ( 0019") (0000 to .0024") 60 aleroinches 5 =CRANKSHAFT Diaantor of aain Journals A... 2nd undersize pee tat undersize Disaster of crankping & ‘et oversize 2nd oversize Thickness of sain bearings Co. 5 | = Dianeter of seat for unin bearings in crankcase Fo... see os Standard Longth of central Journal D +. dist oversize Ind oversize Thickness of thrust rings for central Journal E st oversize Ind oversize End play af crankshaft Hoses see eee eee boo Clearance betveen Journals and aain bearings (*) . . 50,980 to 59,079 an ( 2.2606 to 59,708 to 59,719 an ( 2.2506 to 59.482 to 59.465 an ( 2.3407 to 14.983 to 44.925 an (1.77156 to 44,700 to 44,721 an (1.76156 to 14,585 to 44,467 an (1.75133 to 1,829 to 1,956 to 2,083 to 63,557 te 1,835 an ( 0720 to 1,962 aa ( 070 to 2.089 ma ( 0820 to 63,675 a (2.5062 to 30,000 te 0.127 te 20,254 to 0.05 we (1.1811 to 20.162 a (1.1861 to 0,200 ae (1.1911 to 2.31 to 2.374 to 2.438 to 2.382 we ( 0910 to 2.425 wa ( 0925 to 2.400 wa ( 0980 to 075 to 262 an (002 to O16 to 058 ae ( 0005 to (*) Clearance = aatn bearing 1D - (twice bearing thickness ~ Journal 0D). ne { fain Journals and crankping Gt pin on flyvheel sige 62 ain Journals & crankoing surface roughness. Naxiaua elongation of ain Journals and crankpins . . 17 to 17 to 089 to 26 to 24 an ( 4a ae ( 007 aa Maximus taper of asin Journals and crakping eeasurad oa thelr full length os + 5 + + aries error of parallelise of wain journals and crankpinsweasured on their full Havloun afsallgnment alToved between aain Journals. . faxiavs atsalignent between q; of the two patrs of erankpine and q; of aain Journals on os om m0 2.3611") 2.3511") 2m") 17am") 176200") A.T5ta9") ort) ame ) 0822" ) 2.5069" ) 11,1824") 41,1674") 1.1924") 0929") 0854") 0980") 010") 0022") 082" ) a5) 16 alcroinches (00027) (00039) (.000se") (.c0029") Conte ) =iutcH Pedal free travel... eee Distance between thrust ring and the reference sleeve of tool C. 6.0104 (red dot). Squaraness of the clutch deiven plate assoubled on gearbox direct drive shaft . ear Vinit of driven plate thickness frea length... Tength under test load test load se. tim ttn { free “Length Yength under test load test load... ating of springs B= GEBARBO Ast guar 2nd gear 2rd gear sth gear Sth gear Reverse gear Transatssion rattos . Maxiaun eccantricity of sain shaft assembly... ities 23 me (.9") 75 to 1,25 an (029 to 053") 50 an (,019") 8 an (236) 83 to 46 an (1.69 to 1.91") 29.2 an (1.150*) 44.5 t0°49.5 fg (98.1 to 109.1 Ibe) 48,5 to 51.5 an (1,97 to 2.02") 23.4 an (1.1574) 50 to 54 Xo (110 to 119 tbs) aot 191 wit 10021 Bt Ort 0S aa (.020") 15 to 34 an (,008 to .013*) 85 an (.022*) Gear ‘ree Vength length under test oad Calibration of spring for striking rod balls Va 7 test load st speed gear 2nd § Jed speed gear Sth speed gear & Rey Yarinun end play of the 1st speed gear Ind 8 Jed speed gear Sth speed gear fadial clearance between gear bushings and eainshaft Distance betweon auter planes of the engaging teeth of 3rd and sth gears Distance, in neutral, of the rear band (propeller shaft side) of Sth speed Sleeve frou the rear edae of gear engaging teeth . ‘st = tad = ed 15.2 an (,s00") 10 an (.290°) 2.88 t0 3.12 Kg (5.4 to 6.8 Ibs) 30,5 a0 (1,2") 20 an (.78") 4,32 to 4.68 Xp {9.5 to 10.3 Ibs} 0096") 170 to 245 am (.0087 to 130 to 208 a (0052 t t o0st*) 190 to 220 ae (0063 to 0087") 0067") 0055") 0041") 2125 to 170 an (0048 to 095 to 140 an (0028 to 065 to 107 a (0026 to 42 to 42.2 wm (1,85 to 1.86") 12.9 ae (508) =eWt gear... tnd guar... Trenatsstoncarle overall rattonouith M1:r 8 final detve ses ¢ MEOH ee ath ger... Sth gear... Marinus eccontetelty of axle shafts fee 10/ an (,004") Backlash of differential gears... eee eee ee 8000 05 wa (002") facklash of bevel deve see OS to 10 wo (002 to 004") Reference dinansion an tool C.5.0101 for pintonsto=riag gear f¥tting wee Me 0025 wn (2.7558 +0001") Prectoad on platon bearing. ss a 11,5 to.15.5 Kgea (10 to 13.5 tn, Ibs) Total preload bevel drive bearings . 6 5 sees MOS to 2.5 tygen (14.4 to 21.3 In, Ths) fax, factory end play between resection trunnion and attacheent to body 6... 5s 9 nal (.00¢) 125 te 190 Kos (298 to 418 Ibs) 10 to 55 Kg (42 to 121 Ibs) 50 to 80 Kos {111 te 178 tbs), 9 to 22 Kee (20 to 48 tbs) High speed. lov sped oe eee CHECKING OF SUSPENSION SPRINGS Free length . 437 ae (17.28) Colored arks: Length under test Toad oe ee ee 252 an (10°) nea Blue-inite Test load + 288,7 to 785.3 Kgs (582 to 628 Tbs) =.Bront suspension ADJUSTAENT OF CLEARANCE 14 WEEL BEARING hen perforaing regular servicing or whenever the rasoval of vieel hubs 1s required, adjust the bearing clearance as fellovs: 1) Screw in the nut and Tock It to a torque of 245 Soe ( 18 Toefl ) while at the same tine revolving th tub to set the bearings properly In thelr seats; 2) Unscrew the nut half a turn or sore; 3) Lightly tap on the stub axle end vith a anllet Sn order to return tha outboard besring In Its proper position fen In the case a slight Interforence between beortag cone and stub axle exists: 4) Lock the nat tn place to 1.5 tga (10,8 Theft): 5) Unscrov the aut of a quarter turn; 8) Hf the hole tn the axle ts aligned vith a slat tn the castellated mut insert the eetter pin; If nat, screw in the mut by the sinisue angle needed to Tine up the hole and the next slots 7) Again tap Vightly on stus axle end to restore the sese condition as under step 8) The and play 30 obtatoed om stub axle should fall betveen 02 = 12 an (0008 - 0047") steel WHEEL SEARING _WUORLCATING _twsTRUCTIONS e ‘The quantity of lubricating grense should be about &5 granses (24 a7s) for each hub; do not exceed such a ‘quantity to avold bearing overheating, grease leakage, etc. The graese should be vell distributed inside the bearings and Into side recesses, Subsequently, at the eogular schedule, resove the hub cover end pack the outboard bearing. BALL_JonaTs End play of lover ball Joint tn Its socket... ee eee 1 on (048) Hote Gall Joints require no regular Tubeicat ion beiog provided vith special grease seals vhich retain the grease in by factory on assenbly = Only if strictly needed (Joints squealing) grease vith SHELL Retinax Aor AGIP F 1 Grease 20 (See 1.5, 1,05.097/1). (SRECKING_OF SUSPENSION SPRINGS Free length oes ees 203 wo (11.94) Colored asrka: Length under test load...» 200 on (7.8" ) 716 to 826 Hy (1720 to 1825 Tbe ) Ee ee Test load CHecKI_oF SEX sBSOREERS 4 TEST 4H Calibration date (when cold) GIRLING ET [[teteraton Conprenaton | Extension | _Conressi | N10 to TO Kos 27 to 52 Kos, 190 to 190 Kos | 55 to 80 Kos High spowd so sess s+ [ (Aga to tat tbe) | (60 to 116 hw) | (324 to 448 Ibe)} (121 te 178 tbe) ‘3D to 52 Kot, 9 to 22 Kos. % to 55 hos 9 to 22 Kos ee es (65 to 116 ths) | (20 to 48 tbs} | ($6 to 121 Ths}] (20 te 48 the) =BRAKES (ATS make Dise han 1 brake disc 1s replaced It 1s necessary to check it for runeout after Installation: = use a dial indicator and the special tool A.2.0151 which 1s eounted to the caliper by seans of the pad retaining pins. Maxiaun peraisstble run cut as measured at the svept aurface should not exceed 220 (.0088*). Lote - runout readings can be sisleading If bearing clearance 1s not as specified: therefore, check and adjust 1f necessary, according to factory instructions, If the dise 2 scored, see 1,5. 0.00,055/3:the grioding of the surfaces 18 alloved providing net to excend an une |, equalized on both faces, 1.0. .5 an (0107) each face; disc wear Ital we (2059) Inspection specifications after regrinding of disc surfaces: = Max, out of parallelisa with dise sounting plane: .05 ae ( 0020"); = ax, out of flat: .025 aa (.0010") and ase. difference tn thickness: .038 wa (.0015*) 1s aeasured along any rae 1 ne; = Max, out of f1 cular Vine = The surface should shev no sign of scoring or porosity. 025 wa (,0010") and sax. difference (n thickness: 015 ae (,0006*) ax seamured along any ciro ‘The surface roughness should be: = 26 alcrotnches as aeasured circularly; = 36 aleroinches as sestured radially, Talckness when ney Mew Unit oo. Catipers On replacesent of disc or caliper, aeasure the running clearance between caliper and disc on each side; the diffe= rence should not exceed 5 an (.0107"), To centralize the caliper about the disc, tasert shtus between caliper and sounting flange ax required, It Is aechentcally operated and acts on the rear vheels through sultable shoes which spread apart against 2 drue faachined in the disc casting For « betaf description and repair and suintenance instructions refer tor ATE DISC BRAKES Publication no, 1202. Wate = vhan reassonbling the operating lovers, a slight quantity of grease AGIP FT Gr SK or SHELL Ret inax 1 is to de applied to the plvot plonts apd rubbing surfaces of levers. =WEBEL ALTONMENT AND CAR "TRO Put the car undor static load, with shock absorbers and stabilizer rod connected, vith full tank or equivalent with spare wheel, tool kit and the tires Inflated as spectfi Before checking, slightly Jolt the car 40 as to settle the muspensions,, Zvotghts of 45 Kgs (160 Tbs) 00 front seats State load 2 weights of 25 Kgs (55 Ibs) on Flooring whore feet DISTANCE OF LOVER WISHBONE OF FRONT SUSPENSION FROA_A REFERENCE LEVEL Wd = W300 (10 x 12) = for surpentions having the upper Liaiting buspar out ‘side the spring, AeB should be: 14 3 an (.55 + .12*) Dinension A must be seasured tn corresponde over line of wishbone shaft as shown, f the To adjust, odd shtas tn (1), Shing are avatlable In the folloving thicknesses : 35 am (108) = 7 me (288) - 10,5 ae (428) = 18.DISTANCE OF REAR AXLE FROM RUREER BUFFERS Com 15 +5 on (50 47") = To adjust, remove the saat 3 and adé shies tn 2 as shown, Shins are available In the following tcknesses: 6.5 a0 (26) ‘115 am (.45*) 16,5 we (.65) AS oe (85) {In the condition es specified check the wheel angler, The difference in caster angle between RM, and LN, wheel must not exceed 0°20# Ta adjust, loosen jen nut 0 and ratste red E, Seal] adjustaonts of the caster angle allov to correct slight drift tendency of the car, NB. = Before checking the castor angle shake the front end of ear in order ti front slanting ara to set properly,‘FROWD WHREL CAVEER Difference in caaber angle between RAM, and LAK, wheel = 0° 40 Hote Sot adjustable, Check the chassis and suspension ares If necessary. FROWY WEEL TOE-IN fod Yongth: side. trike eee 272 to 268 we (10,7 to 11.28) 520 to 550 ae (20,06 to 71.66) With the tocsin as specified, the length of reds at seasured betveon ball joint centers should fall within the Maite shown, If these values conot be restored, the caute will probably be attributable to distortion af the box dy resulting frou a colltston,