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Routine maintenance and servicingServicing SpecificationsMaintenance - component locationIntroductionIntensive maintenanceEngine oil and filter renewal (6000 Mile (10
000 Km) / 6 Month Service)Front and rear brake pad/shoe check (6000
Mile (10 000 Km) / 6 Month Service)Fluid leak check (6000 Mile (10 000 Km) / 6
Month Service)Seat belt check (6000 Mile (10 000 Km) / 6
Month Service)Exhaust system check (6000 Mile (10 000 Km) /
6 Month Service)Roadwheel security check (6000 Mile (10 000
Km) / 6 Month Service)Choke adjustment check (6000 Mile (10 000 Km)
/ 6 Month Service)Engine idle speed check (6000 Mile (10 000 Km)
/ 6 Month Service)Mixture adjustment check (6000 Mile (10 000
Km) / 6 Month Service)Spark plug check (6000 Mile (10 000 Km) / 6
Month Service)HT lead, distributor cap and ignition circuit check (6000
Mile (10 000 Km) / 6 Month Service)Hinge and lock check and lubrication (6000
Mile (10 000 Km) / 6 Month Service)Ignition timing and contact breaker gap (dwell angle) check - OHV
engines (6000 Mile (10 000 Km) / 6 Month Service)Throttle damper operation check (6000 Mile
(10 000 Km) / 6 Month Service)Battery terminal check (12 000 Mile (20 000
Km) / 12 Month ServiceEngine valve clearance check - OHV engines (12
000 Mile (20 000 Km) / 12 Month Service)Handbrake check (12 000 Mile (20 000 Km) / 12
Month Service)Auxiliary drivebelt check (12 000 Mile (20
000 Km) / 12 Month Service)Spark plug renewal (12 000 Mile (20 000 Km) /
12 Month Service)Gearbox oil level check (12 000 Mile (20 000
Km) / 12 Month Service)Contact breaker point renewal and distributor lubrication - OHV engines (12
000 Mile (20 000 Km) / 12 Month Service)Steering and suspension security check (12
000 Mile (20 000 Km) / 12 Month Service)Underbody inspection (12 000 Mile (20 000 Km)
/ 12 Month Service)Brake pipe and hose check (12 000 Mile (20
000 Km) / 12 Month Service)Road test (12 000 Mile (20 000 Km) / 12 Month
Service)Crankcase ventilation system check (12 000
Mile (20 000 Km) / 12 Month Service)Air cleaner temperature control check (24 000
Mile (40 000 Km) / every 2 years)Emission control filter element renewal - CVH engines (24
000 Mile (40 000 Km) / every 2 years)Air cleaner element renewal (24 000 Mile (40
000 Km) / every 2 years)Brake hydraulic system seal and hose renewal (36
000 Mile (60 000 Km) / every 3 years)Brake hydraulic fluid renewal (36 000 Mile
(60 000 Km) / every 3 years)Timing belt renewal - CVH engines (36 000
Mile (60 000 Km) / every 3 years)Front wheel alignment check (36 000 Mile (60
000 Km) / every 3 years)Engine coolant renewal (Every 2 years
(regardless of mileage)OHV engine repair proceduresSpecificationsGeneral informationOperations possible without removing engine from vehicleOperations only possible with engine removed from vehicleCylinder head - removal and refittingValve clearances - adjustmentSump - removal and refittingRocker gear - dismantling and reassemblyCrankshaft front oil seal - renewalPistons/connecting rods - removal and refittingOil filter and pump - removal and refittingEngine/transmission mountings - removal and refittingEngine/transmission - removal and separationEngine - dismantlingEngine - examination and renovationCylinder head and pistons - decarbonisingEngine - reassemblyEngine/transmission - reconnection and refittingCVH engine repair proceduresSpecificationsGeneral informationOperations possible without removing engine from vehicleOperations only possible with engine removed from vehicleTiming belt - inspection, removal and refittingCamshaft oil seal - renewalCamshaft - removal and refittingCylinder head - removal and refittingCrankshaft front oil seal - renewalSump - removal and refittingPistons/connecting rods - removal and refittingEngine/transmission mountings - removal and refittingOil filter - renewalEngine/transmission - removal and separationEngine - dismantlingEngine - examination and renovationCylinder head and pistons - decarbonisingEngine - reassemblyEngine/transmission - reconnection and refittingCooling, heating and ventilation systemsSpecificationsGeneral information and precautionsCooling system - draining, flushing, refillingThermostat - removal, testing and refittingRadiator fan - removal and refittingRadiator - removal, repair and refittingCoolant pump - removal and refittingDrivebelt - removal, refitting and tensioningExpansion tank - removal and refittingHeater controls - adjustmentHeater controls - removal and refittingHeater blower motor - removal and refittingHeater - removal and refittingHeater - dismantling and reassemblyCoolant temperature gauge sender unit - removal and refittingFuel and exhaust systemsSpecificationsGeneral information and precautionsAir cleaner element - renewalAir cleaner - removal and refittingFuel pump - testing, removal and refittingFuel tank - removal and refittingFuel tank - cleaning and repairThrottle cable - removal, refitting and adjustmentThrottle pedal - removal and refittingChoke cable (Ford carburettors) - removal, refitting and adjustmentCarburettors (all types) - dismantling and reassemblyFord 1V carburettor - adjustmentFord 1V carburettor - removal and refittingFord VV carburettor - adjustmentFord VV carburettor throttle damper - removal, refitting and adjustmentFord VV carburettor manual choke unit - removal and refittingFord VV carburettor - removal and refittingWeber 2V carburettor - adjustmentWeber 2V carburettor - removal and refittingWeber 2V DFTM carburettor - adjustmentWeber 2V DFTM carburettor - removal and refittingWeber 2V TLD carburettor - adjustmentWeber 2V TLD carburettor automatic choke unit - removal and refittingWeber 2V TLD carburettor - removal and refittingWeber (1V) TLM carburettor - adjustmentWeber (1V) TLM carburettor - removal and refittingExhaust and inlet manifolds - removal and refittingExhaust system - renewal and repairEmission control components - maintenance and testingEmission control components - removal and refittingMechanical ignition systemSpecificationsGeneral information and precautionsSpark plugs, HT leads and distributor cap - inspection and servicingContact breaker gap - adjustmentContact breaker points - renewalIgnition timing - checking and adjustmentDistributor advance - checkingDistributor - removal and refittingDistributor vacuum unit - renewalCondenser - renewalDistributor - overhaulIgnition lock cylinder - removal and refittingElectronic ignition systemSpecificationsGeneral information and precautionsSpark plugs, HT leads and distributor cap - inspection and servicingDistributor - removal and refittingDistributor - overhaulIgnition timing - adjustmentIgnition amplifier module - renewalIgnition lock cylinder - removal and refittingStarting and charging systemsSpecifications1 General information and precautionsBattery - removal and refittingBattery - maintenanceAlternator - removal and refittingAlternator drivebelt - removal, refitting and tensioningAlternator - testingAlternator brushes and regulator - renewalStarter motor - removal and refittingStarter motor - testingStarter motor - brush renewalBraking systemSpecificationsGeneral information and precautionsHydraulic system - bleedingFront disc pads - inspection, removal and refittingFront caliper piston assembly - removal, overhaul and refittingFront brake disc - examination, removal and refittingRear brake linings - inspection, removal and refittingRear wheel cylinder - removal, overhaul and refittingRear brake drum - inspection and renewalMaster cylinder - removal, overhaul and refittingBrake pressure control valve - removal and refittingBrake hydraulic pipes - removal and refittingVacuum servo unit - removal and refittingHandbrake - adjustmentHandbrake cables - renewalHandbrake lever - removal and refittingBrake warning lamps - renewalSuspension and steeringSpecificationsGeneral information and precautionsSteering wheel - removal and refittingSteering column - removal and refittingSteering gear bellows - renewalTie-rod end balljoint - renewalSteering gear - removal and refittingSteering angles and wheel alignmentFront hub bearings - inspection, removal and renewalFront suspension lower arm - removal, bush replacement and refittingFront tie-bar - removal and refittingFront suspension strut - removal, overhaul and refittingRear hub bearings - removal, refitting and adjustmentRear shock absorber - removal, testing and refittingPanhard rod - removal, bush renewal and refittingRear anti-roll bar - removal, bush renewal and refittingRear coil spring - removal and refittingRear axle and suspension unit - removal and refittingRear axle unit - removal and refittingBodywork and fittingsSpecificationsGeneral informationMaintenanceMinor body damage - repairMajor body damage - repairBonnet - removal and refittingBonnet components - removal and refittingRadiator grille - removal and refittingTailgate - removal and refittingTailgate components - removal and refittingDoors - removal and refittingDoor components - removal and refittingDoor windows - removal and refittingTailgate and fixed rear quarter windows - removal and refittingWindscreen - removal and refittingInterior mirror - removal and refittingBumpers - removal and refittingSpoilers - removal and refittingFacia crash padding and vents - removal and refittingSunroof components - removal and refittingSeat belts - removal and refittingSeats - removal and refittingRear wheel arch cover - removal and refittingBody mouldings - removal and refitting