Engine:
Detailed diagnostics, disassembly, inspection, repair, and reassembly of the Zephyr-Six engine, including tuning procedures.
Cooling System:
Radiator, water pump, thermostat, hoses, fan, and coolant specifications.
Fuel System:
Carburetor (likely Solex or Zenith), fuel pump, fuel lines, fuel tank servicing, and adjustments.
Exhaust System:
Muffler, exhaust pipes, manifold, and associated fittings.
Clutch:
Clutch assembly, pressure plate, friction disc, release bearing, and hydraulic/mechanical linkage.
Gearbox:
Manual transmission (likely 3 or 4-speed), gear shifting mechanisms, internal components, fluid changes, and maintenance.
Rear Axle:
Differential assembly, axle shafts, bearings, seals, and lubrication.
Rear Suspension:
Leaf springs, shock absorbers, locating arms, and associated bushings.
Front Suspension:
Independent front suspension (likely with wishbones, coil springs, kingpins/ball joints), shock absorbers, and alignment.
Steering Gear:
Steering box, steering column, linkages, kingpins, and wheel alignment adjustments.
Braking System:
Hydraulic drum brakes (likely Girling or Lockheed), master cylinder, wheel cylinders, brake shoes, drums, fluid specifications, and bleeding procedures.
Wheels And Tyres:
Wheel types, bolt patterns, tire pressures, and replacement recommendations.
Electrical System:
12-volt system (likely post-war conversion or early adoption), generator, battery, starter motor, ignition system (distributor, coil, plugs), lighting, wiring diagrams, gauges, and accessories.
Windscreen Wipers:
Wiper motor, linkages, and blade replacement.
Accessories:
Heating system, radio (if factory fitted), and other auxiliary equipment.
Bodywork:
Panel repair, door mechanisms, window operation, trim, and basic structural information.
Maintenance Procedures:
Regular servicing, lubrication points, fluid changes, filter replacements, tune-ups, and preventative maintenance tasks.
Repair Procedures:
Step-by-step instructions for disassembling, repairing, and reassembling all major mechanical and electrical components.
Diagnostic Procedures:
Troubleshooting guides for common problems, symptom-based diagnostics, and specific test procedures for various systems.
Adjustment Procedures:
Carburetor tuning, ignition timing, brake adjustments, clutch adjustment, and suspension alignment.
Special Tools:
Identification and usage of specialized tools required for specific repair or maintenance tasks.
Depth Of Coverage:
Comprehensive, suitable for full rebuilds and in-depth diagnostics. Covers both routine maintenance and major overhaul procedures.
Detail Level:
Detailed exploded diagrams, torque specifications, clearances, and assembly sequences are expected.
Oil Change Interval:
Typically 3,000 miles or 3 months (using period-appropriate oil).
Grease Points:
Regular lubrication of suspension, steering, and chassis components via grease nipples.
Tune Up Frequency:
Recommended every 6,000-12,000 miles or annually, including ignition timing, carburetor adjustment, and spark plug check/replacement.
Engine Oil:
API SE/SF classification (or equivalent for period oil), viscosity typically SAE 20W-50 or SAE 30.
Coolant:
Water with anti-freeze and anti-corrosion additives. Specific coolant type as per manual.
Gearbox Oil:
API GL-4 gear oil, viscosity SAE 80W-90 or SAE 90.
Rear Axle Oil:
API GL-5 gear oil (hypoid type), viscosity SAE 90.
Brake Fluid:
DOT 3 or DOT 4 hydraulic brake fluid (check manual for specific recommendation, likely DOT 3).
Common Wear Items:
Kingpins, tie rod ends, clutch components, brake shoes/cylinders, engine mounts, exhaust system corrosion, radiator leaks.
Electrical Issues:
Wiring harness degradation, generator/regulator faults, starter solenoid issues, and corrosion in connections.
Bodywork Corrosion:
Susceptible to rust in sills, wheel arches, floor pans, and around window seals due to period construction methods.
