Engine Mechanical:
Engine teardown, rebuild, component specifications, torque values, timing, valve adjustments.
Engine Fuel System:
Carburetor (Weber 40 DCNF), fuel pump, fuel lines, fuel filter, fuel tank servicing.
Ignition System:
Ignition timing, spark plugs, distributors, ignition coils, wiring.
Cooling System:
Radiator, fan, water pump, coolant flow, hoses, thermostat replacement.
Lubrication System:
Oil pump, oil filter, oil pan, lubrication passages, oil specifications.
Transmission Manual:
Gearbox overhaul, clutch replacement, synchromesh, shift linkage adjustment, fluid specifications.
Drivetrain:
Differential, driveshafts, CV joints, wheel bearings.
Suspension Front:
Double wishbone, coil springs, shock absorbers, bushings, geometry adjustment.
Suspension Rear:
Transverse wishbones, trailing arms, coil springs, shock absorbers, bushings, geometry adjustment.
Steering System:
Steering rack, tie rods, steering column, power steering system (if applicable).
Braking System:
Brake discs, calipers, master cylinder, brake lines, brake fluid, parking brake, bleeding procedures.
Electrical System Charging:
Alternator, voltage regulator, battery, wiring.
Electrical System Lighting:
Headlights, taillights, turn signals, interior lights, wiring diagrams.
Electrical System Instruments:
Tachometer, speedometer, gauges, warning lights, wiring.
Electrical System Accessories:
Wipers, washers, horn, power windows (if equipped).
Bodywork And Chassis:
Frame inspection, body panel removal/installation, glass replacement, seals.
Interior Trim:
Dashboard, seats, door panels, headliner, carpeting.
Heating And Ventilation:
HVAC system components, controls, ducting.
Routine Maintenance:
Oil changes, filter replacements, spark plug checks, fluid level checks, tire pressure.
Troubleshooting:
Diagnostic procedures for common and uncommon faults across all systems.
Engine Rebuilding:
Complete engine disassembly, inspection, component replacement, and reassembly.
Transmission Overhaul:
Detailed steps for gearbox disassembly, repair, and reassembly.
Brake System Repair:
Caliber overhaul, master cylinder replacement, brake line repair/replacement, pad/disc replacement.
Electrical Diagnosis:
Wiring diagrams, component testing, fault finding.
Suspension Alignment:
Specifications and procedures for setting wheel alignment.
Carburetor Tuning:
Adjustment and rebuilding of Weber 40 DCNF carburetors.
Clutch Replacement:
Step-by-step guide for clutch assembly replacement.
Body Panel Replacement:
Guidance on removing and refitting exterior body panels.
Glass Replacement:
Procedures for replacing windshield, side, and rear glass.
Depth:
Comprehensive: Covers basic maintenance to full engine and transmission rebuilds.
Diagnostics:
Advanced diagnostic procedures and troubleshooting guides.
Wiring Diagrams:
Detailed electrical wiring diagrams for all systems.
Exploded Views:
Abundant exploded views and diagrams for clear component identification and assembly.
Illustrations And Pictures:
Numerous illustrations and pictures to guide repair processes.
Oil Change Interval Km:
Every 5,000 - 7,500 km or annually
Major Service Interval Km:
Every 15,000 - 20,000 km (includes valve adjustment, ignition tune-up)
Timing Belt Replacement:
N/A (Chain-driven camshafts)
Engine Oil Type:
SAE 20W-50 or 10W-40 (API SG or higher, synthetic recommended for modern use)
Engine Oil Capacity Liters:
Approx. 8.0 liters (with filter)
Coolant Type:
Ethylene Glycol based antifreeze (50/50 mix with distilled water)
Brake Fluid Type:
DOT 3 or DOT 4 (high boiling point)
Carburetor Issues:
Synchronization and tuning of the four Weber carbs can be complex. Susceptible to gumming if not used regularly.
Cooling System:
Potential for overheating if cooling system maintenance is neglected; fan switch issues can occur.
Electrical System:
Aging wiring harnesses can lead to intermittent electrical faults.
Suspension Bushings:
Rubber bushings deteriorate over time, affecting handling and requiring replacement.
Rust Ingress:
Can be susceptible to rust in sills, wheel arches, and underbody if not properly maintained/stored.
Clutch Release Bearing:
Can wear out, leading to noise or difficulty disengaging the clutch.